Related Manuals for Nilfisk-Advance Clarke Focus II Large
Summary of Contents for Nilfisk-Advance Clarke Focus II Large
- Page 1 Cla rke Foc us I I La rge Se r vic e M a nua l Cla rke M ode ls: 5 6 3 8 1 7 9 6 (Foc us I I D-C AU S), 5 6 3 8 1 8 2 5 (Foc us I I D), 5 6 3 8 1 8 2 8 (Foc us I I D-C) 6/12 revised 11/13 FORM NO.
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Page 2: Table Of Contents
Table of Contents Ta ble of Cont e nt s Introducion...........5 Nameplate Other Manuals Available For Your Machine Convenions... - Page 3 Table of Contents Removal and Installaion Solenoid Valve Removal Solenoid Valve Disassembly and Cleaning Soluion Filter and Ball Valve Removal Scrub System ..........37 Funcional Overview M2/M3 - Scrub Brush Motor Run Funcion M5 - Scrub Brush Actuator Lit Motor Funcion...
- Page 4 Table of Contents Electrical System ..........67 Wiring (Ladder) Diagram Wiring Harness Diagram 56315926 Rev.
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Page 5: Nameplate
Introduction Introduction This manual will help you get the most from your Clarke Focus II Large Autoscrubber. Read it thoroughly before servicing the machine Note: Bold numbers and letters in parentheses indicate illustrated items Note: All references to right, left, front, or rear in this manual are as seen from the operator’s standpoint... -
Page 6: Cauions And Warnings
Introduction Cautions and Warnings Symbols It is important for you to read and understand this manual The information it contains relates to protecting your safety and preventing problems The symbols below are used to help you recognize this information Danger! Indicates a potentially hazardous situation which, if not avoided, will result in death or serious injury. -
Page 7: General Safety Instrucions
Introduction General Safety Instructions Warning! ◦ This machine should be used only by properly trained and authorized persons ◦ Never work under a machine without safety blocks or stands to support the machine ◦ Keep sparks, lame and smoking materials away from batteries. Explosive gases are vented during normal operation ◦ Charging the batteries produces highly explosive hydrogen gas. Charge batteries only in well- ventilated areas away from open lame. Do not smoke while charging the batteries. -
Page 8: Technical Speciicaions
Introduction Technical Specifications Voltage 36-Volt Power Source (6) 6-volt Batteries (wet acid and gel cell available) Battery Capacity 305 amp-hrs. Protection Grade IPX3 Onboard Battery Charger 36-volt, 25-amp Wet/Gel Compatible Solution Control Pulse-control gravity feed Solution Tank 30 gal. (114 L) Recovery Tank 30 gal. - Page 9 Introduction Technical Specifications (continued) 9 - FORM NO. 56043162 - Focus II Large...
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Page 10: Maintenance Schedule
Introduction Maintenance Schedule Maintenance intervals given are for average operating conditions Machines used in severe operational environments may require service more often. MAINTENANCE ITEM Daily Weekly Monthly Yearly Charge the Batteries Check/Clean Tanks and Hoses (clean recovery tank switch and vacuum inlet screen) Check/Clean/Rotate the Brushes/Pads Check/Clean the Squeegee Check the Water Level in each Battery Cell (does not apply to gel cell batteries) Inspect the Brush Housings... -
Page 11: Pm Checklist
Advance 34 RST Models PM Checklist Defect Codes Customer needs adjustment binding Address dirty or contaminated damaged, bent or torn City leaks missing Model Serial No. Hours W worn out Does OPERATIONAL INSPECTION ITEMS Defect Codes (circle) Work Palm Drive Button and Reverse Button Operation (check for Fwd/Rev Drive) Drive System Performance (Speed Changes Min/Max) noisy sluggish Scrub System (Raise/Lower, Brush Motor On/Off) -
Page 12: Know Your Machine
Introduction Know Your Machine As you read this manual you will occasionally run across a bold number or letter in parentheses - example: (2). These numbers refer to items shown on the following pages unless otherwise noted Refer to these pages for the location of items highlighted in bold in the text. Solution Tank Fill Scrub Deck Bumper Wheel Operator Control Handle 10 Drive Wheel Bottle Holders 11 Solution Filter Vacuum Motor Inlet Screen 12 Solution Shutoff Valve... - Page 13 Introduction 16 Solution Drain Hose/Level Indicator 25 Squeegee Mount Thumb Nut 17 Squeegee Raise/Lower Lever 26 Squeegee Adjustment Knob 18 Battery Pack Connector (non onboard charger models only) 27 Recovery Tank Drain Hose 19 Recovery Hose 28 Reverse Button 20 Wheel Drive Circuit Breaker 29 Palm Drive Buttons 21 Circuit Breaker for the Control Circuit 30 Speed Limit Control Knob...
- Page 14 Introduction Control Panel Assy Motor, Right Brush Speed Control Motor, Vac Battery (Not Shown) Motor, Brush Actuator Fuse, 150 Amp Potentiometer, 100K Ohm, Speed Limit Circuit Breaker, 5 Amp Switch, Key Circuit Breaker, 30 Amp Switch, Float (Recovery Tank Full) Contactor, Brush Motor Switch, Reverse Contactor, Vac Motor...
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Page 15: Control Panel
Control Panel Control Panel Key Switch (Main Power) Scrub ON Switch Solution Switch I1 – Regular Scrub ON Indicator B1 Solution Indicator I2 – Heavy Scrub ON Indicator D1 Solution Flow Indicator I1 and I2 – Extreme Scrub ON Indicators Vacuum Switch Display C1 Vacuum System Indicator... -
Page 16: Funcional Descripion
Control Panel Functional Description The control panel is an integral component with the Main controller (A1) circuit board The controls on the 34 RST were designed with one touch operation in mind. For single-pass scrubbing the user can simply depress one switch and all systems on the machine will be ready to go. For most single-pass scrubbing operations, the operator should only need to use the middle switches on the control panel These are the Scrub System OFF and Scrub System ON switches Key Switch (A): The key switch serves as a main control switch to enable or disable operation of the machine The key is removable to prevent unwanted operation when not in use The key switch doesn’t disconnect any power... -
Page 17: Descripion Of Indicators
Control Panel Description of Indicators Each of the switches on the control panel have an indicator LED adjacent to the switch Most LEDs are dual channel and provide two colors within the same LED In general, the following guidelines apply to the control panel indicators, and various exceptions to this rule are listed separately: • A steady green indicator means that the particular system or function is on • A lashing green indicator means that the particular system is in a delayed-off condition. An example of this is... -
Page 18: Scrub Mode Indicators
Control Panel Scrub Mode Indicators The Solution system and Scrub system have three scrub modes (regular, heavy, and extreme). These scrub modes are jointly Extreme controlled when the Scrub On Switch (I) is pressed, but the Solution system can be controlled separately by pressing the Heavy Solution Switch (B) Regular • Pressing the Scrub On Switch (I) once will set both the scrub mode and solution mode to regular (and clear any solution... -
Page 19: Main Controller
Control Panel Main Controller The Main controller (A1), which includes the control board and the display, is the primary electronic control for the machine and its functions (except drive control). The control board is the basic input/output device and contains a micro- contoller chip to regulate function The controller receives and interprets user inputs, sensor inputs, and even some motor amperage readings, and controls device output for the user display, solenoid operation, and motor control Most low and medium power outputs are controlled with power MOSFET... -
Page 20: Displaying The Control Board Revision Level
Control Panel Displaying the Control Board Revision Level During machine service, it may be helpful to know the control board revision level to determine machine coniguration. To view the control board revision level: Turn the key switch to the off position While holding the Solution (B) and Vacuum (C) switches depressed, turn on the key switch Hold both switches until Solution and Vacuum indicators turn green. -
Page 21: Low-Voltage Cutout Threshold
Control Panel Low-voltage Cutout Threshold The 34 RST is equipped with a low-voltage cutout feature to prevent over-discharging the batteries. This feature will automatically shut down the scrub system when the battery voltage falls to the selected threshold The cutout threshold has two levels: Standard and Alternate The Standard setting is 30 96 volts (5 16 volts per battery), and is for standard lead acid batteries The Alternate setting is 32 58 volts (5 43 volts per battery), and is for typical gelled electrolyte batteries. Select the proper cutout level based on the battery manufacturer’s speciications. Factory Default: 30 96V (Standard Battery) -
Page 22: Scrub Deck Down Time Period Adjustment
Control Panel Scrub Deck Down Time Period Adjustment The initial lowering of the scrub deck is timed, because there will not be any brush motor amperage to monitor for determining when to stop lowering the deck The time that the deck is lowered is adjustable from 3 5 seconds to 4 4 seconds in 0.1-second increments. The factory default setting is #5, 4.0 seconds. To adjust the scrub deck down time, perform the following steps: Turn the key switch to the off position... -
Page 23: Scrub Deck Pressure, Soluion Flow Rate, And Chemical Flow Rate Adjustments
Control Panel Scrub Deck Pressure, Solution Flow Rate, and Chemical Flow Rate Adjustments Each of the scrub settings (Regular, Heavy, and Extreme) affects the scrub deck pressure and solution low rate. These settings are adjustable The default values are shown in the tables below The scrub pressures are determined by examining the amperage through the brush motors. Scrub Pressure & Amperage Specifications Chart Default Pressure Brush Motor Scrub Mode Indicator... -
Page 24: Heavy Scrub Seing Adjustment
Control Panel Press the Scrub Off switch (H) to save the new setting and move to the end of the program mode 10 Turn the key switch to the off position The new settings will be saved and will remain in effect until they are changed again Heavy Scrub Setting Adjustment: Use this procedure to adjust the scrub deck pressure and solution rate that are used for the Heavy scrub mode. -
Page 25: Troubleshooing Guide
Control Panel Troubleshooting Guide Any error codes detected by the main control board will be displayed on the display panel as they occur. If more than one error exists the display will sequence through the error codes at one-second intervals. The hour meter / error display (J2) will lash an “E” and 2 numbers, one at a time. When troubleshooting any “Fault Description” noted with a double asterisk (**) follow the instructions for entering the Service Test Mode in the control board’s special programs See the Main Control Board Special Program Options section in this manual Main Controller Error Codes Error... - Page 26 Control Panel E017 Scrub deck lift actuator circuit The controller’s internal circuitry is not seeing any voltage change. open (**) • Inspect the B+2 bus (J2-7) and fuse (F2) for positive battery voltage. • Check for disconnected actuator wiring or defective actuator motor.
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Page 27: Main Controller I/O Table
Control Panel Main Controller I/O Table B- = Battery Negative B+ = Battery Positive Signal Nominal Reference Designation Pin Wire Color Description Range Comments Type Value Pulsed Signal equal to the Fault Code lashed by the Speed Input J1-4 ORN/BLU Speed Control Status -36V 37.6 - 30.6V... -
Page 28: Service Test Mode
Control Panel Service Test Mode To assist in the troubleshooting and servicing of the electrical system and related components, a special test mode allows independent control of the various outputs and monitoring of the various inputs To enter the service test mode perform the following step: Turn the key switch to the off position While holding the Vacuum switch (C) depressed, turn the key switch to the on position... -
Page 29: Test Mode Output Controls
Control Panel Test Mode Output Controls The control panel switches are used to control various output functions of the Main controller while in Test Mode Below is a list of each switch and the function it controls Following the list is a detailed description of each function Scrub off Switch (H): Controls the brush motors Scrub on Switch (I): Controls the scrub deck lift actuator Vacuum Switch (C): Controls the vacuum motor... - Page 30 Control Panel Scrub On Switch (I) This switch is used to control the output to the scrub deck lift actuator Pressing and releasing this switch will cycle the actuator output through 4 states These are: 1 – Output off, direction = up 2 –...
- Page 31 Control Panel • Check the Blk wire of the main harness connector at the vacuum motor to battery Positive If no voltage repair or replace wire Flashing Yellow – Vacuum motor overload has occurred • Check for an open in the small ORG current sense wire • To conirm an overload, disconnect the motor plug from the main harness, run a 30 amp fused test leads from the batteries to the motor and perform an Amp draw test. Normal current load 36V 16-19 Amps.
- Page 32 Solution System Solution System Functional Overview The main body of the machine also serves as the solution tank. The solution tank has a ill capacity of 30 gallons (114 liters). All models use one right rear tank ill opening for ease of illing. A serviceable Solution Filter is plumbed into the manual solution shutoff valve outlet to keep debris from entering the solenoid valve. Also itted to the tank is a lexible drain hose that also serves as a water level sight tube. The solution system uses an electrical Solenoid Valve (L1) which stops and starts the solution low to the scrub brushes The electrical circuit that turns on (energizes) the solenoid coil is activated through the (A1) control panel’s solution switch button input and the FWD / REV (A2) Speed Controller voltage output signals Note: See the Know Your Machine section in this manual for a complete explanation of the solution operation modes.
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Page 33: Circuit Overview
Solution System Circuit Overview The 34 RST machines do not use a solution pump. The gravity-fed solution rate is controlled by cycling the solution solenoid on and off at the rates shown in the table below. The three solution low rates listed are managed by the A1 control board’s negative voltage output from the terminal J1-11 Red/Grn wire. This input from A1 to the solution solenoid also requires negative voltage from Pin 6 - Brake on the speed controller (A2) to J1-5 – For/Rev. on A1 (Red/ Blk wire). The J1-11 Red/Grn L1 solenoid circuit turns on and off to open and close the L1 solenoid which controls the three different solution low rates by gravity feed only. The total solenoid cycle time is approximately six seconds. The solution low is proportional to the time the solenoid is on (open) during the total solenoid cycle time. The approximate solenoid on/off times corresponding to the three solution low rate is shown in the table below. Solution Indicator Flow Rate Solenoid On Time Solenoid Off Time One-bar gauge 0.3 g/m 2 sec. 4 sec. Two-bar gauge 0.6 g/m 4 sec. 2 sec. Three-bar gauge 0.9 g/m 6 sec. -
Page 34: Maintenance
Solution System Maintenance • Solution Tank: Empty the solution tank weekly; remove the solution Drain Hose from its storage area (located on the right rear control handle compartment). Direct the hose to a designated “Disposal Site” and lush the tank with clean water • Solution Filter: Remove and clean the inline Solution Filter. To access the ilter housing for removal, work underneath the middle right rear side of the machine’s chassis. No tools are needed to remove the ilter (hand tighten only) Service Tip: The solution manual shutoff valve must be placed in the OFF (Closed) position This prevents loss of solution when servicing the ilter strainer with a partial or full tank. Troubleshooting Guide Problem Possible Cause Inadequate or no solution low No solution in the tank Solution tank ilter ball valve in the off position Clogged solution ilter, solenoid valve or hoses... -
Page 35: Removal And Installaion
Solution System Removal and Installation Solenoid Valve Removal Drain the solution tank or turn off the solution ball valve to prevent solution loss Shut off the key switch and disconnect the battery connector Note: You may want to jack up the left side of the machine for better access to the Solenoid Valve (H) and associated hardware. If you choose to jack up the machine, make sure you support the machine with safety stands or blocking to prevent the machine from dropping and possibly causing personal injury or machine damage. Warning! Never work under machine without safety stands or blocking to support the machine. -
Page 36: Soluion Filter And Ball Valve Removal
Solution System Solution Filter and Ball Valve Removal Drain the solution tank using the solution drain hose (B). Loosen the 2 Hose Clamps (R) and carefully remove (pry off) the solution Inlet Hose (S) and Outlet Hose (T) from the Filter/Valve Assembly (F) Remove the 2 Hose Clamps (U) that secure the Filter/Valve Assembly (F) to the chassis and remove the Filter/ Valve Assembly (F) from the machine 36 - FORM NO. -
Page 37: Scrub System
Scrub System Scrub System Functional Overview The 34 RST models use the disc-type scrub system powered by (2) 3/4 HP motor gearbox assemblies. Note: Recovery Tank Full switch must be open (Tank empty). On all models the scrub deck platform is raised and lowered automatically by a vertically-mounted electric lift actuator motor. The operation of the machine’s scrub functions are activated when the operator selects (presses) the scrub on (mode) panel button The scrub pad or brush pressure ranges (1-3) are selectable allowing the operator the choice to vary the scrubbing effort (pressure) while operating the machine Note: See the Electrical System/Main Control Programming Options section in this manual for more detailed operation and instructions on how to change the factory default regular... -
Page 38: Electrical Diagram
Scrub System Electrical Diagram FIGURE 1 FUSE, 150 A. FUSE, 150 A. BATTERY BATTERY 36 VDC CONTROL BOARD J2-7 CIRCUIT BREAKER, 5 AMP CIRCUIT BREAKER, 5 AMP VIO/YEL J2-1 BRUSHACTUATOR2 VIO/BLK WHT/GRN J1-14 J2-8 BRUSHCONTACTOR BRUSHACTUATOR1 MOTOR, BRUSHACTUATOR MOTOR, BRUSHACTUATOR COIL, BRUSHMOTORCONTACTOR COIL, BRUSHMOTORCONTACTOR J2-4... -
Page 39: Removal And Installaion
Scrub System Removal and Installation Motor Gimbal Make sure the scrub brush deck is in its raised position, then turn the key switch off and disconnect the battery pack Caution! Disconnect the battery pack connector before servicing machine. See Figure 2. Unlatch and remove the left- and right-hand Brush Housings (A and B) Push the brushes/pads straight down to remove them from the Motor Gimbals (C) Remove the 5/16”-18 Socket Head Screw (D) using a ¼” hex wrench, then remove the Motor Gimbal (C), Brush Driver Collar (E) and Key (F) from the scrub motor shaft... -
Page 40: Scrub Brush Deck
Scrub System Scrub Brush Deck With scrub brushes installed, lower the scrub brush deck, turn the key switch off and disconnect the battery pack Caution! Disconnect the battery pack connector before servicing machine. Note: If the battery pack is connected and the key switch is switched on when the scrub brush deck is lowered, the deck will automatically rise to its upper limit. This could cause personal injury or machine damage. Remove the front nose cone by irmly grasping the lower part and lifting straight up. See Figure 2. Unlatch and remove the left- and right-hand Brush Housings (A and B) See Figure 3. Disconnect the Solution Hose (G) from the Coupler Barb (H) See Figure 2. -
Page 41: Scrub Brush Lit Actuator
Scrub System Scrub Brush lift Actuator See Figure 3. With scrub brushes installed, lower the scrub brush deck, turn the key switch off and disconnect the battery pack Note: If the lift actuator motor will not run, go to step 2, then shim up the brush deck to relieve the pressure on the connecting hardware to ease removal of the Lift Actuator Assembly (T). Remove the front nose cone by irmly grasping the lower part and lifting straight up. Disconnect the actuator motor wiring harness pigtail connector Service Note: If you have an optional Actuator Power Cord Adapter (Advance Part #56407502), you can use the Adapter to run the lift actuator up or down to relieve the pressure on the connecting hardware and ease removal of the Lift Actuator Assembly T). -
Page 42: Scrub Brush Motor/Gearbox
Scrub System Scrub Brush Motor/Gearbox Remove the scrub deck from the machine following the steps in the Scrub Brush Deck Removal section Turn the brush deck on its back See Figure 2. Remove the brushes/pads from the Motor Gimbals (C) If removing both Motor / Gear Unit Assemblies (J), mark the location of the Assemblies on the Deck Weldment (N) for correct reassembly Remove the 5/16”-18 Socket Head Screw (D) holding the Motor Gimbal (C) to the motor output shaft, then remove the Motor Gimbal (C), Brush Driver Collar (E) and Key (F) Make sure to save the Key (F) -
Page 43: Recovery System
Recovery System Recovery System Functional Overview See Figure 1. Dirt and water are lifted off the loor into the recovery tank by airlow created by a three-stage 36V vacuum motor. The wastewater and air enter the vacuum system at the squeegee tool through small openings (notches) in the front squeegee blade. The small openings are the entrance points for the water and air and help speed up the airlow, producing the suction to lift the wastewater off of the loor. The air and wastewater move through the squeegee hose at high speed until the wastewater reaches the recovery tank. There the air slows down because of the increased volume (large size) of the tank With the decreased air speed, the heavier water falls to the bottom of the recovery tank. The airlow continues through the tank, vacuum fan inlet screen and vacuum motor, and is exhausted out of the vacuum exhaust hose. No wastewater ever actually moves through the vacuum motor, just the working air The vacuum system uses a loat switch to prevent the tank from being overilled and stops any water from being sucked into the vacuum motor. -
Page 44: Vacuum Motor Control Circuit Overview (Auto Mode)
Recovery System Vacuum Motor Control Circuit Overview (Auto Mode) + (Positive) Circuit input starts with: • A closed S3 key switch supplies the needed positive voltage to the A1 control board J1-13 (Brn wire). Note: The A1 control board scrub-on button must also be depressed (enabled). This operator command lowers the brush deck • A closed 5-amp circuit breaker (F2) supplies positive battery voltage (Brn wire) to the control side of the vacuum motor contactor coil (K2) • Once the load side of K2 is closed, the needed positive battery voltage is supplied to motor M4 - (Negative) circuit input starts with: • Battery negative ground inputs at the A1 control board terminals B-1 (J1-7), B-2 (J1-9), B-3 (J2-9) and B-4 (J2-6) at the A2 speed controller terminal B-. -
Page 45: Maintenance
Recovery System Maintenance Service Maintenance Checklist Whenever there is a vacuum problem, it’s best to check over the entire system Use the checklist below as a guide to thoroughly check the vacuum system □ Inspect and clean the vacuum motor loat switch. (If the switch is closed [tipped up] the vacuum motor will not operate) □... -
Page 46: Maintenance Of The Recovery Tank Float Switch
Recovery System Maintenance of the Recovery Tank Float Switch If the recovery tank loat switch becomes dirty it can impair the operation of the recovery system. A dirty vacuum shutoff switch can cause the vacuum motor to not function at all, or fail to shut off when the tank is full If daily rinsing of the recovery tank is not suficient to keep the switch clean you may need to remove the loat arm for cleaning. The loat arm can be removed easily by grasping it as shown below and twisting to remove. It is very important that the loat switch be reassembled correctly in order to function. See Figure 3 for the correct orientation of the switch loat arm. FIGURE 3 46 - FORM NO. -
Page 47: Maintenance Of Vacuum Motor Inlet Screen
Recovery System Maintenance of Vacuum Motor Inlet Screen See Figure 4. The Vacuum Motor Inlet Screen (4) should be cleaned on a daily basis DO NOT run water down the screen in an attempt to clean it If you do this you will be running water directly into the vacuum motor To remove the Vacuum Motor Inlet Screen (4) from the recovery tank, grip, twist and pull up on the Vacuum Motor Inlet Screen (4) FIGURE 4... -
Page 48: Removal And Installaion
Recovery System Removal and Installation Vacuum Motor Removal Drain the Recovery Tank (A) using the drain hose Turn the key switch off and disconnect the battery pack Swing open the recovery tank and disconnect the vacuum motor harness connector See Figure 5. Carefully pull the Acoustical Foam vacuum exhaust hose (B) out of the P-Clamp (C) on the Recovery Tank (A) Remove the (4) Phillips Pan Head Screws (D) and Flat Washers (E) holding the Vacuum Motor Shroud (F) to the bottom of the Recovery Tank (A), then remove the Vacuum Motor Shroud (F) -
Page 49: Recovery Tank Removal
Recovery System Recovery Tank Removal If you wish to remove the vacuum motor from the Recovery Tank (A), do so by following steps 1-6 in the Vacuum Motor Removal section Disconnect the electrical connector to the Float Switch (K) Note that you may need to cut a cable tie to access the connector Loosen the Hose Clamp (L) and disconnect the Drain Hose (M) from the Recovery Tank (A) Loosen the clamp and disconnect the Vacuum Hose Assembly (N) from the Recovery Tank (A) -
Page 50: Squeegee System
Squeegee System Squeegee System Maintenance Squeegee Lift Linkage Adjustment See the Know Your Machine section in this manual. The squeegee pick-up tool is raised and lowered manually by a rear control panel mounted Lever (17) Squeegee Lift Lever Adjustment The squeegee tool’s storage and operating positions are adjustable. To adjust the squeegee position: Lower the squeegee assembly to the loor. See Figure 1. Note that the squeegee mount weldment has three Mounting Holes (A) for changing the up / down squeegee positions. Remove the Nyloc Nut (B) from the Hex Head Screw (C), then remove the Hex Head Screw (C), lat Washer (D), Cable Bushing (E) and attached cable assembly from the squeegee mount weldment. Reinstall in the Hex Head Screw (C), lat Washer (D) Cable Bushing (E) and attached cable assembly into the appropriate hole to raise or lower the squeegee positions as needed, then reinstall the Nyloc Nut (B) Make sure that the squeegee lift cable has ample free play when the squeegee is lowered. Note: This allows... -
Page 51: Servicing The Squeegee
Squeegee System Servicing the Squeegee If the squeegee leaves narrow streaks or water, the blades may be dirty or damaged. Remove the squeegee, rinse it under warm water and inspect the blades Reverse or replace the blades if they are cut, torn, wavy or worn To Reverse or Replace the Rear Squeegee Wiping Blade: See Figure 2. Raise the squeegee tool off the loor, and then unsnap the Center Latch (23) on the squeegee tool Remove the Tension Straps (22) Slip the rear blade off the Alignment Pins (24) The squeegee blade has four working edges. Turn the blade so a clean, undamaged edge points toward the front of the machine Replace the blade if all four edges are nicked, torn or worn to a large radius Install the blade, following the steps in reverse order and adjust the squeegee tilt. -
Page 52: Removal And Installaion
Squeegee System Removal and Installation Squeegee Mount Assembly Removal Turn the key switch off and disconnect the battery pack See Figure 3. Disconnect the Squeegee Hose (19) and remove the Squeegee Assembly (13) from the machine Lower the Squeegee Lever (17) and disconnect the Squeegee Lift Cable (C) from the Squeegee Mount Assembly. Service Note: The downward spring force on the squeegee mount weldment can make it dificult to remove and reinstall the Squeegee Mount Assembly. You may choose to remove the squeegee level Wheels (F) from the Squeegee Mount Assembly, or jack up the machine to reduce the effect of the downward spring force. Note: If you choose to jack up the machine, make sure you support the machine with safety stands or blocking to prevent the machine from dropping and possibly causing personal injury or machine damage. Warning! Never work under machine without safety stands or blocking to support the machine. Remove the Screw (D) through the access hole in the bottom of the chassis and slide the Squeegee Mount Assembly (E) away from the chassis Reinstall by following the above steps in reverse order Make sure the spacer bushing is installed on the Screw... -
Page 53: Caster Wheel Removal
Squeegee System Caster Wheel Removal Turn the key switch off and disconnect the battery pack Warning! Never work under machine without safety stands or blocking to support the machine. Drain both the solution and recovery tanks. Remove the squeegee assembly and have the scrub brush deck in the up (stored) position with the scrub brushes installed See Figure 4. Place Wood Blocking (H) in front of the drive wheels to prevent the machine from rolling Jack the machine in the location shown until the caster wheel is approximately 1” off the ground. -
Page 54: Wheel Drive System
Wheel Drive System Wheel Drive System Functional Overview See Figures 1 and 2. A 375 watt (0.5 HP) permanent magnet (36V) motor transaxle (M1) is used for the wheel drive on all machines A Curtis PMC solid state speed controller (A2) regulates the variable speed and Fwd/Rev wheel drive motor functions The controller is located in the rear electrical compartment (accessible by removing the six screws securing the top main control panel). Two palm drive buttons, wired in parallel, actuate the transaxle drive motor A reverse button controls the machine reverse A speed limit pot R1 (knob adjusted) mounted in the handle regulates the machine’s maximum transport and scrub speeds. -
Page 55: Electrical Diagram
Wheel Drive System Electrical Diagram Note: For a complete description of all callouts see the Electrical System/Wiring Diagram/Schematic section in this manual FIGURE 2 FUSE, 150 A. FUSE, 150 A. BATTERY BATTERY 36 VDC CONTROL BOARD J2-7 CIRCUIT BREAKER, 5 AMP CIRCUIT BREAKER, 5 AMP J2-1 BRUSHACTUATOR2 J1-14... -
Page 56: A2 Speed Controller Pin Key Detail
Wheel Drive System FIGURE 3 WHEEL DRIVE SYSTEM A1 Speed Control Pin Connection 4.7K POT WIPER POT HIGH R1 Speed Limit 100K Ohms POT LOW This drawing shows additional controller input circuit detail. The R1 speed limit pot is shown at its maximum speed setting, with the wiper pin #18 shorted to the pot high pin #3 A2 Speed Controller Pin Key Detail PIN# WIRE COLOR CONTROLLER DESCRIPTION and FUNCTION... -
Page 57: Wheel Drive Troubleshooing Guide
Wheel Drive System Wheel Drive Troubleshooting guide Problem Possible Cause No wheel drive in Forward or Reverse • Wheel drive motor circuit breaker (F3) tripped (reset 30A circuit breaker). • Control circuit breaker (F2) tripped (reset 5A circuit breaker). • Defective S6 &... -
Page 58: Removal And Installaion
Wheel Drive System Removal and Installation Drive Motor Transaxle Removal Turn the key switch off and disconnect the battery pack Warning! Disconnect the battery pack before servicing machine. Warning! Never work under machine without safety stands or blocking to support the machine. Drain both the solution and recovery tanks and remove the squeegee. -
Page 59: Drive Motor Transaxle Removal (Coninued)
Wheel Drive System Drive Motor Transaxle Removal (continued) Service Note: You may ind it easier to loosen the wheel Nuts (A) slightly when the wheels are still on the ground and before you jack up the machine. See Figure 5. Jack the front of the machine from this location until the drive wheels are approximately 1” off the ground Remove the (6) wheel Nuts (A) and remove the (2) Drive Wheels (B) from the Motor Transaxle (D) Disconnect the drive motor wiring connector Remove the (4) Motor Mount Bolts and Nuts (C), and the two Transaxle Mount Plates (E) and carefully slide the Motor Transaxle (D) away from the machine Reinstall the Motor Transaxle (D) by following the above steps in reverse order Note that the tapered ends of the wheel Nuts (A) go against the Drive Wheels (B) -
Page 60: Drive Wheel Removal
Wheel Drive System Drive Wheel Removal Turn the key switch off and disconnect the battery pack Warning! Disconnect the battery pack before servicing machine. Warning! Never work under machine without safety stands or blocking to support the machine. Remove the squeegee. Place wood blocking in the front and rear of the Drive Wheel (F) opposite of the one that you are removing to prevent the machine from rolling Service Note: You may ind it easier to loosen the wheel Nuts (G) slightly when the wheel is still on the ground and before you jack up the machine. -
Page 61: Tesing The Palm Drive Butons
Wheel Drive System Testing the Palm Drive Buttons See Figure 7. Disconnect the Handle Harness (H) from the mating connector located to the left of the squeegee raise/lower handle See Figure 8. Use a continuity checker or ohmmeter to check the continuity between pins 4 and 6 on the Handle Harness (H) When the palm drive buttons are working correctly: • The circuit through pins 4 and 6 should be open when both palm drive buttons are released • The circuit through pins 4 and 6 should be closed (approximately zero ohms) when either of the palm drive buttons is pressed... -
Page 62: Palm Drive Buton Replacement
Wheel Drive System Palm Drive Button Replacement Note: It’s recommended that you empty the Recovery Tank before replacing a Palm Drive Button. See Figure 7. Remove the (2) Phillips Flat Head Screws (I) and remove the Palm Switch Assembly (J) from the Handle (K) See the detail in Figure 7. Remove the (2) Phillips Pan Head Screws (L) and Flat Washers (M) and remove the Palm Button Switch (N) and (2) Switch Springs (O) from the Palm Switch Housing (P) Be careful not to lose the Switch Springs (O) Remove the Retaining Nut (Q) and Star Washer (R) from the SPST Momentary Switch (S), then remove the SPST Momentary Switch (S) and the other (2) Star Washers (T) from the Palm Switch Housing (P) -
Page 63: Tesing The Reverse Buton
Wheel Drive System Testing the Reverse Button See Figure 9. Disconnect the Handle Harness (H) from the mating connector located to the left of the squeegee raise/lower handle See Figure 8 Use a continuity checker or ohmmeter to check the continuity between pins 3 and 5 on the Handle Harness (H) When the reverse button is working correctly: • The circuit through pins 3 and 5 should be open when the reverse button is released • The circuit through pins 3 and 5 should be closed (approximately zero ohms) when the reverse button is pressed... -
Page 64: Reverse Buton Replacement
Wheel Drive System Reverse Button Replacement Turn the key switch off and disconnect the battery pack Note: It’s recommended that you empty the Recovery Tank before replacing the Reverse Button. Pull the Drain Hose out of the brackets to access the 5/16”-18 Hex Head Screws (U & Z) Disconnect the Handle Harness (H) from the mating connector located to the left of the squeegee raise/lower handle. (This will prevent excessive pulling or stress on the Handle Harness (H) and connector when the Handle (K) is swung down to remove the Access Plate (V) ) Loosen the bottom left- and right-hand 5/16”-18 Hex Head Screws (Z) holding the Handle (K) to the machine Remove the top left- and right-hand 5/16”-18 Hex Head Screws (U) holding the Handle (K) to the machine, then... -
Page 65: Tesing The Speed Limit Control Poteniometer
Wheel Drive System Testing the Speed Limit Control Potentiometer See Figure 9. Disconnect the Handle Harness (H) from the mating connector located to the left of the squeegee raise/lower handle See Figure 8 Use an ohmmeter on pins 1 and 4 to check the total resistance of the potentiometer If the potentiometer is working correctly, the resistance across pins 1 and 4 should measure approximately 100K ohms Use an ohmmeter to measure the resistance across pins 2 and 4 If the potentiometer is working correctly: • The resistance across pins 2 and 4 should measure 100K ohms with the Speed Limit Control Knob rotated all the way counterclockwise (slow speed) • The resistance across pins 2 and 4 should measure close to zero ohms with the Speed Limit Control Knob... - Page 66 Wheel Drive System 15 Check the position of the gray indicator on the Knob (AA) with the Potentiometer (AB) set to both the full clockwise (fast) and full counterclockwise (slow) positions Readjust the rotational position of the Knob (AA) on the Potentiometer (AB) shaft as necessary to center the indicator to the Handle (K) 16 Reconnect the Handle Harness (H) to the connector on the machine 17 Snap the Drain Hose back into the brackets.
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Page 67: Electrical System
Electrical System Electrical System Wiring (Ladder) Diagram (OPTIONAL) ONBOARDBATTERY CHARGER NOTE: CONNECT GRNWIRE TOF2 ANDDISCONNECT REDWIRE FROMF2 FORCHARGEROPTION INTERLOCK BLK/WHT CIRCUIT BREAKER, 5 AMP CIRCUIT BREAKER, 5 AMP FUSE, 150 A. FUSE, 150 A. BATTERY BATTERY 36 VDC CONTROL BOARD J2-7 CIRCUIT BREAKER, 5 AMP CIRCUIT BREAKER, 5 AMP... -
Page 68: Wiring Harness Diagram 56315926 Rev. C
CONTROL BOARD J1 J1 J2 J2 VIO/BLK 18-1 BLK 18-6 BLK 18-5 BRN 16-1 BLU/BLK 20-1 YEL/VIO 18-1 WHT/GRA 18-1 BLK/YEL 18-1 RED/BLK 20-1 ORN 18-1 GRA/WHT 18-1 RED/GRN 18-1 ORN/BLU 20-1 BLK 18-4 WHT/GRN 18-1 BLK 16-2 BRN 16-8 VIO/YEL 18-1 WHITE BROWN... -
Page 69: Bateries
Electrical System Batteries Description of the Low Voltage Cut-Out Feature All models discussed in this manual are equipped with a low voltage cut-out feature to prevent over-discharging of the batteries. When a machine’s battery pack voltage falls below speciically deined thresholds (voltage settings), the scrub system is automatically shut down. The cut-out level is adjustable. -
Page 70: Batery Maintenance
Electrical System Battery Maintenance Charging Batteries Charge the batteries each time the machine is used or when the battery indicator (1 or 3) is reading less than full Note: Refer to the algorithm chart in Advance Technical Service Bulletin TSBUS2008-984 for the correct charging algorithm for your battery type and model. Caution! • Charge batteries in a well-ventilated area. • Do not smoke while servicing the batteries. •... -
Page 71: Removal And Installaion
Electrical System Removal and Installation Caution! • Use extreme caution when working with batteries. Sulfuric acid in batteries can cause severe injury if allowed to contact the skin or eyes. • Explosive hydrogen gas is vented from the batteries through openings in the battery caps. Do not smoke while servicing the batteries. -
Page 72: Maintenance And Adjustment
Electrical System Maintenance and Adjustment Lift Actuator Limit Adjustment To protect the lift actuator from traveling too far, it contains two internal limit switches for minimum and maximum travel The minimum travel is adjusted by turning the leadscrew nut, and the maximum travel (or length) is adjusted by turning the dial at the top of the leadscrew motor This adjustment requires the use of the Actuator Power Cord Motor Adapter (1) (PN 56407502) shown to the right... - Page 73 Electrical System 10 Remove the dust cap (6) from the top of the gear housing (5) using your ingers or a small screw driver. 11 Place a 1/2” socket (9) over the limit adjustment nut (7) to turn the nut, and increase or decrease the lower limit as follows: • Important: Even though the center of the adjustment nut looks like it Turn Outer will accept a screwdriver blade, this is the retainer for the adjustment...
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Page 74: Curis Controller Diagnosics
Electrical System Curtis Controller Diagnostics Diagnostics Method A: Uses the machine’s LED display and the Regular Scrub ON indicator. Function of the Speed Controller Status Light and Display The Curtis 1228 speed control will output a fault code if there is a problem associated with the speed control and wheel drive system When the Curtis controller presents an error to the main controller, the display will indicate an “E03”... -
Page 75: Drive Status Led Fault Codes
Electrical System Drive Status LED Fault Codes TABLE 1 Status Light Explanation Possible Cause Code Display over-/under-temperature cutback 1. Temperature >92°C or < -25°C. 2. Excessive load on vehicle. 3. Operation in extreme environments. 0 00 throttle fault 1. Palm drive switch wires open or shorted. 2. -
Page 76: Speed Control Programming Opions
Electrical System Speed Control Programming Options Following are the two speed control parameters that can be adjusted using a Curtis handheld programmer: M1 MAX SPD – Forward Transport/Scrub maximum speed limit (% of full throttle) M1 REV MAX SPD – Reverse Transport/Scrub maximum speed limit (% of full throttle) Installation Checkout for the Curtis Speed Controller After installing a controller and before operating the vehicle, carefully complete the following checkout procedure If you ind a problem during the checkout, refer to the Curtis Controller Diagnostics section for further information...
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