Page 1 SC5000 Service Manual Advance Models: Nilfisk Models: 56117001 566117805 860D 56117003 56117807 810C 56117004 56117808 910C Language Form No. 56043181 Rev C, 2023...
Page 2: Table Of Contents
Service Manual – SC5000 Contents 03 - General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 General Machine Description Service Manual Purpose and Application Other Reference Manuals and Information Sources...
Page 3 Service Manual – SC5000 Service Menu A1 Main Controller A3 Power Module A4 Drive Controller Output Test Deck Lift Panel Test Options Menu Configuration Menu System Menu Impact Log Troubleshooting Main Controller (A1) Error Codes Power Module (A2) Error Codes User Interface (A9) Error Codes Specifications Sample Shop Voltage Measurements...
Page 4 Service Manual – SC5000 24 - Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Functional Description Low Voltage Cutout Onboard Battery Charger...
Page 5 Service Manual – SC5000 Column Harness and Main Harness-Front Traction Harness Main Harness, Rear Electrical Connector Pin-Out Assignments 30 - Solution System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Functional Description Shutoff Valve Solution Solenoid...
Page 6 Service Manual – SC5000 Brush Motor Brush Motor Brushes Specifications Special Tools Actuator Test Kit 38 - Squeegee System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201 Functional Description Squeegee Lift Actuator Squeegee...
Page 7: 03 - General Information
Service Manual – SC5000 03 - General Information General Machine Description The SC5000 machine is a battery-powered, ride-on, self-propelled commercial floor scrubbing machine with either a disc or cylindrical scrub system, and suitable for use in commercial applications. The machine is available with one of three deck types.
Page 8: Parts And Service
• Hydrometer • Battery load tester for checking batteries • Set of torque wrenches These tools are also available from Nilfisk-Advance, Inc.: • Vacuum water lift gauge, p/n 56205281. Conventions All references to right, left, front and rear in this manual are as seen from the Operator’s position.
Page 9: Safety
Service Manual – SC5000 03 - General Information Safety 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 10 Service Manual – SC5000 03 - General Information Property Damage Messages − Storage and operation temperature must be above 0°C and a humidity between 30% and 95%, non-condensing. − Before use, all doors and hoods should be properly latched. − This machine is not approved for use on public paths or roads. −...
Page 11: Transporting The Machine
Service Manual – SC5000 03 - General Information Transporting the Machine Observe the following guidelines when preparing the machine for shipping: • Drain both the recovery and solution tanks. If the tanks are left full or partially full, the sloshing solution may make the load unstable.
Page 12: Lifting The Machine
Service Manual – SC5000 03 - General Information Lifting the Machine CAUTION: Never work under a machine without safety stands or blocks to support the machine. − Drain the recovery and solution tanks to prevent sloshing water from unbalancing the machine.
Page 13: Technical Specifications
Service Manual – SC5000 03 - General Information Technical Specifications Advance Model SC5000 32C SC5000 36C SC5000 34D Nilfisk Model SC5000 810C SC5000 910C SC5000 860D Advance Part Number 56117001 56117003 56117004 Nilfisk Part Number Units 56117807 56117808 56117805 Voltage, Batteries Battery Capacity (max) Ah C20 Protection Grade, Operating...
Page 14: Fastener Torque Specifications
Service Manual – SC5000 03 - General Information Fastener Torque Specifications Size Plated Steel Stainless Steel 42 in.-lb. 28 in.-lb. 1/4“ 100 in.-lb. 67 in.-lb. 5/16” 17 ft.-lb. 11 ft.-lb. 3/8” 31 ft.-lb. 20 ft.-lb. Standard Torque 1/2” 75 ft.-lb. 50 ft.-lb.
Page 15: Maintenance Procedure References
Service Manual – SC5000 03 - General Information Maintenance Procedure References • Vacuum Motor Brushes described on page 214 • Disc Brush Motor Brushes described on page 185 • Cylindrical Brush Motor Brushes described on page 198 Lubricate the Machine •...
Page 16: Know Your Machine
Service Manual – SC5000 03 - General Information Know Your Machine Main Assemblies Solution Tank Steering Column Recovery Tank Chassis Squeegee Cylindrical Scrub Deck Disc Scrub Deck...
Page 17: Machine Components
Service Manual – SC5000 03 - General Information Machine Components Front RH View Recovery Tank Cover Headlights (optional) Operator’s Seat Blue Light (optional) Drive Pedal Solution Tank Drain Hose Drive Wheel Front Roller Bumper Rear Wheel Scrub Deck Battery Compartment (under seat) Side Blade Assembly Removal Knobs Warning Beacon Solution Tank Fill...
Page 18: Rear Lh View
Service Manual – SC5000 03 - General Information Rear LH View Tie Down Location (2 rear) Squeegee Mount Thumb Nuts Control Panel Squeegee Caster Lock Knob Recovery Tank Cover Squeegee Assembly Recovery Tank Shutoff Float Hopper (Cylindrical only) Vacuum Motor Filter Housing Scrub Deck Debris Catch Tray Solution Filter...
Page 19: 04 - Control System
Service Manual – SC5000 04 - Control System Functional Description The division of the SC5000 System by logic function starts with the Main Machine Controller (MMC or Main Controller). As the name implies, this acts as the central controller that ties all of the other modules together.
Page 20: Functional Diagram
Service Manual – SC5000 04 - Control System Functional Diagram The Functional Block Diagram represents a high-level overview of the system interactions and communications. It is not intended to show every component or connection. For a more detailed examination of system interconnections, refer to the “Wiring Diagrams”...
Page 21: Drive Controller
Service Manual – SC5000 04 - Control System Drive Controller The drive controller operates and monitors the wheel motor. It generates a 3-phase Pulse Width Modulated (PWM) power control to the wheel motor. Even though it is actually DC power, it resembles a 3-phase system because the polarity reversals and zero-crossings resemble a 3-phase AC system.
Page 22: Power Module
Service Manual – SC5000 04 - Control System Power Module As the name suggests, the power module handles the high-power output functions for the machine. It receives its commands from the main machine controller via the CAN Bus network. The power module provides basic motor control and protection, but the main machine controller controls the actual operation commands for the motors.
Page 23: Main Machine Controller
Service Manual – SC5000 04 - Control System Main Machine Controller As the name implies, the Main Machine Controller (MMC) is the primary controller for the system. The MMC directly or indirectly controls the functions of the machine. Because the MMC controls the on/off function of the whole machine, it is always receiving logic power through the 5 amp circuit breaker, but controls the status of the KSI relay to itself and the other controllers.
Page 24: Main Controller Operational Modes
Service Manual – SC5000 04 - Control System Main Controller Operational Modes The main controller is firmware driven using a micro controller to set operational modes based on machine input and function. These modes of operation are described below. • Normal Modes –...
Page 25 Service Manual – SC5000 04 - Control System – Vac motors M4 and M5 – Wand mode (seat switch open upon entry) or Squeegee Actuator M6 ◦ No recovery system fault (vac motors and squeegee) ◦ No Estop inhibit ◦ No impact lockout inhibit ◦...
Page 26: Control Panel
Service Manual – SC5000 04 - Control System Control Panel The control panel (display) is a standalone controller for receiving user input and displaying machine status to the operator. The display communicates this information with the Main Machine Controller via the CAN(0) bus. Power Button (A): The signal for the On/Off power button passes directly to the Main Machine Controller, even though it is integrated into the control panel.
Page 27: Can Bus Communication
Service Manual – SC5000 04 - Control System CAN Bus Communication CAN Bus communication was originally created for the automotive industry to allow distributed modules (Nodes) throughout the vehicle to communicate with each other over a single serial channel without any single Node being the Master of the communication channel.
Page 28: Component Locations
Service Manual – SC5000 04 - Control System Component Locations Drive Controller Main Machine Controller KSI Relay User Interface Power Module Main Ground Lug K2 Power Relay...
Page 29: Main Machine Controller Programming
Service Manual – SC5000 04 - Control System Main Machine Controller Programming The Main Machine Controller is programmable for machine specific functions and configurations through a text menu system. Various parts of the menu system are hidden, depending on the user level access: User, Supervisor, Technician.
Page 30: Programming Menu Outline
Service Manual – SC5000 04 - Control System Programming Menu Outline Faults Menu A1 Main Controller Active Faults J1-16 B+ (V) Keys Menu Fault History J1-15 KSI Relay Read Key Clear History  J1-12 KSI Key List J2-7 E-Stop J2-5 Seat Switch Hours Menu J2-6 OBC Interlock J1-11 Horn...
Page 31: Hours Menu
Service Manual – SC5000 04 - Control System Hours Menu The hours menu displays the amount of time the machine has been active in each of the listed categories. The On Time represents the total time that the machine has been powered up, regardless whether it was active or sitting neutral.
Page 32: Service Menu
Service Manual – SC5000 04 - Control System Service Menu The Service menu provides access to diagnostic tools for troubleshooting the machine. Except for the Panel Test, each of these entries brings up a submenu for the applicable system module or function. To aid in navigating this information, Menu Level Menu Name these submenus are hyperlinked below:...
Page 33: A3 Power Module
Service Manual – SC5000 04 - Control System Backup Alarm: This is the output to the optional backup alarm. A1 Main Controller Beacon: This is an output indicator to signify when the beacon H8 BACKUP ALARM output is active. LP8 BEACON SOLUTION LEVEL (V) 0.44 Solution Level Sensor: This is an input from the solution level...
Page 34: A4 Drive Controller
Service Manual – SC5000 04 - Control System A4 Drive Controller The Drive Controller menu provides status information about the drive motor and the drive controller itself. A brief summary of each listing is described below. A4 Drive Controller Speed (mph/kph): This displays the actual speed of the machine. Speed (mph/kph) Throttle %: This displays the throttle position as percent of Throttle %...
Page 35: Output Test
Service Manual – SC5000 04 - Control System Output Test The Output Test menu provides manual control of various system functions for troubleshooting purposes. This permits devices to be operated even when prerequisite conditions are not met, such as permitting the solution solenoid to be active without the scrub system active.
Page 36: Panel Test
Service Manual – SC5000 04 - Control System Panel Test The Panel Test screen provides a means to verify the functionality of all of the control panel switches, LEDs, and display pixels. The display shows a graphical representation of all of the control panel switches. When you depress a switch (A), its representation on the screen highlights (B) to show the press was detected.
Page 37: Configuration Menu
Service Manual – SC5000 04 - Control System Inactivity Time (min): This sets the length of time (in minutes) before the machine powers down after inactivity. The minimum is 1 minute, the maximum is 30 minutes, and the increment is every minute. Impact Detect: This sets how the machine handles impact detection.
Page 38: System Menu
Service Manual – SC5000 04 - Control System System Menu System The system menu displays the firmware revision number and the serial number of the control board. It also provides access for MMC Firmware 99.99.99.9 updating the firmware, and checking the impact log. UI Firmware 15.14.0009 Install MMC Firmware...
Page 39: Troubleshooting
Service Manual – SC5000 04 - Control System Troubleshooting Any error codes initiated by any module will be sent to the main controller via the CAN Bus, and shown on the display and recorded to the log. Each of these codes for the main controller and power module are listed in the tables below, along with some basic troubleshooting steps to help isolate the cause.
Page 40 Service Manual – SC5000 04 - Control System 2-047 M7 Deck Act Mtr Overcurrent ......60 2-048 M8 Option Pump Motor Overcurrent .
Page 41: Main Controller (A1) Error Codes
Service Manual – SC5000 04 - Control System Main Controller (A1) Error Codes 1-001 K1 KSI Relay Coil Open (K1 KSI Relay Open) The controller has detected that the KSI relay is not responding Description to a closure command. The controller has commanded the KSI relay to close, but 36 When Monitored Setting volts is not detected at the output contacts.
Page 42 Service Manual – SC5000 04 - Control System 1-002 K1 KSI Rly Coil Short Description The controller has detected a short circuit to the KSI relay coil. When Monitored Setting The amp draw exceeds 5 amps Conditions Always Possible Causes Short in the relay coil.
Page 43 Service Manual – SC5000 04 - Control System 1-003 K1 KSI Contact Weld The controller has detected that the KSI relay output power is active after the Description controller has de-energized the relay coil. When Monitored Setting Power is detected at contacts J1-12 and J1-13 when the KSI Conditions relay is not commanded to be energized.
Page 44 Service Manual – SC5000 04 - Control System 1-010 CAN Bus 0 Description CAN bus 0 is in bus-off state When Monitored Setting Main controller has no response from any other controller on Conditions CAN0 Bus Always Possible Causes CAN0 wires open or shorted Initial Action Reboot the machine Troubleshooting Steps...
Page 45 Service Manual – SC5000 04 - Control System 1-101 Solution Solenoid Short Description Solution solenoid - too much current When Monitored Setting Amp Draw is higher than 5 Amps Conditions Always • Shorted Solution Solenoid Possible Causes • Control wire shorted to power Initial Action None Troubleshooting Steps...
Page 46 Service Manual – SC5000 04 - Control System 1-105 H1 Horn Short Description Horn - too much current When Monitored Setting Amp Draw is higher than 5 Amps Conditions Always • Shorted horn Possible Causes • Control wire shorted to power Initial Action None Troubleshooting Steps...
Page 47 Service Manual – SC5000 04 - Control System 1-201 Level Sensor Description Solution tank level sensor voltage is out of range. When Monitored Setting Conditions Always • Broken sensor Possible Causes • Control wire shorted to power Initial Action None Troubleshooting Steps Disconnect the solution sensor and check if the error persists.
Page 48 Service Manual – SC5000 04 - Control System 1-701 No Comm: A2 Power Mod 1-705 No Comm: A9 Interface Mod 1-710 No Comm: A3 Drive Mod Description Do not see heartbeat messages from respective module. When Monitored Setting Same Conditions Always Possible Causes Internal software issue...
Page 49: Power Module (A2) Error Codes
Service Manual – SC5000 04 - Control System Power Module (A2) Error Codes Power module error codes will be displayed on the main display. However, the error number is also flashed on the two-color status LED on the module itself. The status LED has 2 colors; red and yellow. The red LED will flash out which digit of the code is coming next, and the yellow LED will flash out the value of that digit.
Page 50 Service Manual – SC5000 04 - Control System 2-012 K2 Overload Description Excessive current to the K2 relay coil. When Monitored Setting Relay coil current exceeded 2 amps. Conditions Always Possible Causes Degraded relay coil. Complete failure likely. Initial Action Replace the K2 relay Troubleshooting Steps 2-013...
Page 51 Service Manual – SC5000 04 - Control System 2-014 K2 Contact Open Description K2 Power Module contactor did not close When Monitored Setting The power module did not detect power at the B+ lug when Conditions the K2 relay was commanded to close. Always •...
Page 52 Service Manual – SC5000 04 - Control System 2-018 Undervoltage Cutoff Description Insufficient voltage present at Power Module power supply When Monitored Setting Voltage below 18 volts. Conditions Always Possible Causes Loose or corroded connection Initial Action None Troubleshooting Steps Isolate the cause by systematically checking voltages back to the battery.
Page 53 Service Manual – SC5000 04 - Control System 2-023 M3 Sweep Motor Open Description Sweep motor is open circuit. When Monitored Setting The power module has detected no current on the M3 output Conditions lug. . Always • Disconnected motor. Possible Causes •...
Page 54 Service Manual – SC5000 04 - Control System 2-027 M7 Actuator Motor Open Description The power module has detected an open circuit in the deck actuator circuit. The power module examines the circuit for voltage drop, which When Monitored Setting should be near 0 volts when the motor is not commanded to Bootup Conditions...
Page 55 Service Manual – SC5000 04 - Control System 2-031 M1 Scrub Motor Overload 2-032 M2 Scrub Motor Overload Description M1 or M2 Scrub Motor Overload When Monitored The brush motor uses M1 or M2 outputs. The power module Setting detected current above 70 amps to the brush motor, but less Always Conditions than a short circuit amperage.
Page 56 Service Manual – SC5000 04 - Control System 2-036 M6 Squeegee Act Mtr Overload Description M6 Squeegee actuator motor overload. When Monitored Setting The power module has detected excessive current in the Conditions squeegee lift actuator, but less than short circuit amperage. Always Because the overcurrent condition has reached the maximum permissible amperage Possible Causes...
Page 57 Service Manual – SC5000 04 - Control System 2-041 M1 Scrub Motor Overcurrent 2-042 M2 Scrub Motor Overcurrent The power module has detected scrub motor current has exceeded the limitations of Description the power module. When Monitored Setting The power module detected current above 160 amps to the Conditions brush motor.
Page 58 Service Manual – SC5000 04 - Control System 2-044 M4 Vacuum Motor 1 Overcurrent 2-045 M5 Vacuum Motor 2 Overcurrent The power module has detected vacuum motor current above 160 amps, which Description exceeds the limitations of the power module. When Monitored Setting Same...
Page 59 Service Manual – SC5000 04 - Control System 2-046 M6 Squeegee Act Mtr Overcurrent The power module has detected squeegee actuator motor current above 25 amps, Description which exceeds the limitations of the power module. When Monitored Setting Same Conditions Always •...
Page 60 Service Manual – SC5000 04 - Control System 2-047 M7 Deck Act Mtr Overcurrent The power module has detected deck actuator motor current above 25 amps, which Description exceeds the limitations of the power module. When Monitored Setting Same Conditions Always •...
Page 61 Service Manual – SC5000 04 - Control System 2-051 M1 Mosfet Short 2-055 M5 Mosfet Short 2-052 M2 Mosfet Short 2-056 M6 Mosfet Short 2-053 M3 Mosfet Short 2-057 M7 Mosfet Short 2-054 M4 Mosfet Short 2-058 M10 Mosfet Short Description The power module has detected a short circuit in the output mosfet.
Page 62 Service Manual – SC5000 04 - Control System 2-067 UnderTemp Cutoff Description Internal temperature is below -40C When Monitored Setting Same Conditions Always Possible Causes Power module failure Initial Action If the error doesn’t clear, replace the power module Troubleshooting Steps 2-071 M1 Scrub Motor Overload Trip 2-072...
Page 63 Service Manual – SC5000 04 - Control System 2-074 M4 Vacuum Motor Overload Trip 2-075 M5 Vacuum Motor Overload Trip Description M5 Vacuum Motor Overload When Monitored The power module has detected current above 70 amps for Setting more than 5 seconds in the vacuum motor, but less than a Always Conditions short circuit amperage.
Page 64 Service Manual – SC5000 04 - Control System 2-078 M8 Option Pump Motor Stall Description M8 wash pump motor overload. When Monitored Setting The power module has detected excessive current in the wash Conditions pump, but less than short circuit amperage. Always Possible Causes •...
Page 65 Service Manual – SC5000 04 - Control System 2-083 CAN Bus Fault Description Internal CAN bus error When Monitored Setting Conditions Always Possible Causes Initial Action Reboot the machine. If the error doesn’t clear, replace the power module. Troubleshooting Steps 2-084 Internal Comm Timeout Description...
Page 66 Service Manual – SC5000 04 - Control System 2-087 Under Temp Cutback Description Internal temperature is below -25C - output current will be reduced When Monitored Setting Conditions Always Possible Causes Initial Action If the error persists after the machine has warmed, replace the power module. Troubleshooting Steps 2-088 K2 Coil Open...
Page 67 Service Manual – SC5000 04 - Control System 2-091 M1 Hardware Fault 2-092 M2 Hardware Fault 2-093 M3 Hardware Fault 2-094 M4 Hardware Fault 2-095 M5 Hardware Fault Description Output hardware is defective When Monitored Setting Internal hardware fault Conditions Always Possible Causes Disconnect the respective motor and reboot the machine.
Page 68: User Interface (A9) Error Codes
Service Manual – SC5000 04 - Control System 2-102 Temperature Sensor Fault Description Internal temperature sensor has invalid value When Monitored Setting Same Conditions Always Possible Causes Initial Action Reboot the machine. If the error persists, replace the power module Troubleshooting Steps 2-103 K2 Coil Short...
Page 69 Service Manual – SC5000 04 - Control System Troubleshooting Steps (4-705 Display Lost Comms) Refer to the Wiring Diagram “Appendix A: CAN Wiring” on page 138 for wire tracing information. 1. Measure the resistance between pins 1 and 2 of the X207 CAN diagnostic port located near the MMC. −...
Page 70: Specifications
Service Manual – SC5000 04 - Control System Specifications Sample Shop Voltage Measurements The following tables contain some “real world” shop voltage measurements to help you recognize what “normal” looks like. All voltage values were measured with the black (Negative) voltmeter lead connected to the main battery negative unless otherwise specified.
Page 71 Service Manual – SC5000 04 - Control System J2 Main Machine Controller Pin# Wire Color Function Observations (Empty, 1 sensor, 2 sensors, 3 sensors) Actual: 0.03, 2.39, 4.51, 6.44 mA W120 GRY-BLU Solution Level Return MMC Display: 0.00, 0.24, 0.44, 0.64 (The display numbers are presumed voltage across a 100 ohm internal resistor.) +12V Out...
Page 72 Service Manual – SC5000 04 - Control System J5 Drive Controller Pin# Wire Color Function Observations W165 Potentiometer Gnd W195 CAN-1 H 2.6V W196 CAN-1 L 2.5V W163 BLU-GRY Seat Switch In Open = 0.02V, Seated = B+ W164 BLU-YEL E-Stop In Closed = B+, Open/Active = 0.02V W193...
Page 73 Service Manual – SC5000 04 - Control System J6 Power Module Pin# Wire Color Function Observations W232 BRN-GRY Deck Actuator - Down = 3.8 V, Up = 34.2 V, Stationary = 3.8 V W019 K2 Coil Out W245 CAN-1 L W244 CAN-1 H W240...
Page 74: Maintenance
Service Manual – SC5000 04 - Control System Maintenance Firmware Update Both the Main Controller (MMC) and User Interface (UI) firmwares can be updated using the built-in USB access port below the steering wheel. Note: It is essential that the major release revision of the MMC and the UI are compatible. Having incompatible MMC and UI revisions could result in an inoperable machine.
Page 75: Removal And Installation
Service Manual – SC5000 04 - Control System Removal and Installation Main Machine Controller CAUTION: The main controller is always receiving power, even when the machine is off. Make sure to disconnect the main battery connector before working on the control board. Iff the machine is functional enough to access the service menu, enter the Configuration and Options menus and record the existing values.
Page 76 Service Manual – SC5000 04 - Control System Configure the Controller While holding the Scrub and Vacuum buttons, press and release the power button to start the machine with service-mode access. Press the Information button to enter the menu system, and navigate to the Configuration menu. •...
Page 77: 14 - Wheel System, Non-Traction
Service Manual – SC5000 14 - Wheel System, Non-Traction Functional Description The non-traction wheels are intended to carry the majority of the machine’s weight. The wheels are strategically located below the battery compartment and between the recovery and solution tanks. The non-traction wheels are mounted directly to the machine’s subframe.
Page 78: Removal And Installation
Service Manual – SC5000 14 - Wheel System, Non-Traction Removal and Installation Rear Wheel Bearings and Seal The rear wheel bearings are sealed and do not require lubrication. Severely worn bearings may be detected by wheel wobble or grinding sounds. A less obvious symptom of bearing failure is when the wheel easily freewheels when spun by hand with the machine elevated off the ground.
Page 79 Service Manual – SC5000 14 - Wheel System, Non-Traction Remove the 5 screws (I) that secure the brake rotor to the wheel, and rest the rotor on the axle. Using a sharp tool, such as a knife or chisel, pry the dust cap (L) off the wheel hub.
Page 80: Rear Brake Calipers
Service Manual – SC5000 14 - Wheel System, Non-Traction Rear Brake Calipers Calipers should be replaced in pairs. The calipers are right- and left-handed. The difference between the two is the arrow direction stamped on to the actuator bar, which must point toward the rear of the machine. WARNING: Never work under a machine without safety stands or blocking to support the machine.
Page 81 Service Manual – SC5000 14 - Wheel System, Non-Traction Remove Both Calipers Remove the cotter Pin (J) and disconnect the link arm (K). Slide the caliper off the mounting bracket. 10. Repeat for the second caliper. Check/Adjust the Cable Length Before the calipers can be adjusted, the balance bar (O) must be parallel to the frame and at a known distance.
Page 82 Service Manual – SC5000 14 - Wheel System, Non-Traction Install the Calipers The calipers are right- and left-handed. There is an arrow stamped into the actuator bar (M). Make sure the arrow is pointing toward the rear of the machine when the caliper is mounted.
Page 83: 20 - Drive System
Service Manual – SC5000 20 - Drive System Functional Description The drive system of the SC5000 machine consists of a single drive wheel with an integral motor. The drive wheel connects to the subframe with a rotational bearing and flange to provide steering rotation.
Page 84: Drive Controller
Service Manual – SC5000 20 - Drive System Drive Controller The KSI relay provides logic power to the drive controller. When the main machine controller is not energizing the KSI relay, the drive controller has no logic power. However, the drive controller has unswitched power through the CB2 circuit breaker, which provides separate high-current power output for the motor control.
Page 85: Operational Mode Prerequisites
Service Manual – SC5000 20 - Drive System Operational Mode Prerequisites Before the main controller can activate any of the operational modes, it must first check that the appropriate prerequisites are met. • Drive Controller outputs – Drive wheel motor ◦...
Page 86 Service Manual – SC5000 20 - Drive System 3-019 Quickstop Active Description A drive inhibit signal was activated while the machine was in motion. When Monitored Setting Conditions Always Possible Causes Initial Action Troubleshooting Steps 3-020 Throttle not in Neutral Description The throttle potentiometer was not within the neutral deadband during initialization When Monitored...
Page 87 Service Manual – SC5000 20 - Drive System 3-034 Motor Open Description An open circuit was detected at the output to the wheel motor. When Monitored Setting Conditions Always Possible Causes Initial Action Troubleshooting Steps 3-035 Power Relay Short Description False Error.
Page 88 Service Manual – SC5000 20 - Drive System 3-040 Motor Sensor Error Description Unexpected signals from the 3 commutator sensors. When Monitored Setting Conditions Always Possible Causes Initial Action Reboot the machine. If the error persists, replace the drive controller. Troubleshooting Steps 3-041 Temp Sensor Fault...
Page 89 Service Manual – SC5000 20 - Drive System 3-049 FET Over-Temp The temperature of output power transistors is too high. The machine will be Description operating in thermal cutback. When Monitored Setting Conditions Always Possible Causes Initial Action Troubleshooting Steps 3-050 Motor Over-Temp Description...
Page 90 Service Manual – SC5000 20 - Drive System 3-081 Low FET Error 3-082 High FET Error Description Precharge error with the internal DC Bus during initialization. When Monitored Setting Conditions Always Possible Causes Initial Action Disconnect the battery for 1 minute, and reboot the machine. Troubleshooting Steps 3-083 Throttle Failband...
Page 91 Service Manual – SC5000 20 - Drive System 3-255 Internal Failure Description The drive controller is detecting an internal error. When Monitored Setting Conditions Always Possible Causes Initial Action Reboot the machine. If the error persists, replace the drive controller. Troubleshooting Steps...
Page 92: Removal And Installation
Service Manual – SC5000 20 - Drive System Removal and Installation Drive Controller WARNING: Disconnect the main battery connector before servicing the drive controller. The drive controller has high- amperage, unswitched battery power at its terminals. Turn off the machine and disconnect the main battery connector.
Page 93: Drive Wheel Assembly
Service Manual – SC5000 20 - Drive System Drive Wheel Assembly WARNING: Never work under machine without safety stands or blocking to support the machine. Disconnect the battery connector before servicing machine. Turn off the machine and disconnect the batteries. To reduce the weight of the machine, drain both the recovery and solution tanks.
Page 94 Service Manual – SC5000 20 - Drive System Turn the steering wheel all the way to the right to make the steering chain connections easier to access. Note: There are two options for disconnecting the steering chain from the chain disk. Method 1 is to remove the master link that holds the chain to the tension block, and Method 2 removes...
Page 95 Service Manual – SC5000 20 - Drive System 15. Remove the cotter pin (J) from the castle nut (K). 16. Using a 36 mm socket, remove the castle nut (K) and washer (L). 17. Slowly begin to raise the machine away from the drive wheel.
Page 96: Electromechanical Brake
Service Manual – SC5000 20 - Drive System Electromechanical Brake Disconnect the EM Brake electrical connector (F). Remove the three screws (C) that secure the brake module (D) to the motor. Free up the brake wire from the motor housing, and remove the brake. During replacement, use a screw driver to hold the brake release lever (E) raised.
Page 97: Drive Tire
Service Manual – SC5000 20 - Drive System Drive Tire DELETE??? The drive tire consists of the urethane tire and the metal rim that it is attached to. The drive tire may be replaced without removing the wheel motor assembly from the machine. Pressing the rim off the wheel motor requires the tire pulling kit (56422174).
Page 98 Service Manual – SC5000 20 - Drive System Turn the steering wheel so the other side of the motor is facing outward. 10. Remove the housing screws (J1) from the drive wheel, and replace them with the longer screws from the wheel puller kit. •...
Page 99 Service Manual – SC5000 20 - Drive System Replacement Procedure 12. Apply anti-seize, such as Loctite 8150, to the bearing seat of the replacement wheel. 13. Remove the wheel pulling screws (J2) from the drive housing. Bearing Seat Anti-Seize 14. Attach the original drive hub (D) to the new wheel using 6 new screws (F).
Page 100: Specifications
Service Manual – SC5000 20 - Drive System Specifications Parameter Range Brake Coil Resistance • 54 Ω Sample Shop Voltage Measurements The following table contains some “real world” shop voltage measurements to help you recognize what “normal” looks like. All voltage values were measured with the black (Negative) voltmeter lead connected to the main battery negative unless otherwise specified.
Page 101: 22 - Steering System
Service Manual – SC5000 22 - Steering System Functional Description The drive system on the SC5000 machine consists of a single, steerable drive wheel at the front of the machine. Steering control is made through the steering column that passes through an offset box and a universal joint to translate the rotation from the angled steering...
Page 102: Maintenance And Adjustment
Service Manual – SC5000 22 - Steering System Maintenance and Adjustment Steering Chain Tension Note: If this procedure is being completed because the steering chain was disconnected or serviced, it is best to confirm that the steering wheel is oriented correctly before the chain is 1/4 Inch tensioned.
Page 103: Removal And Installation
Service Manual – SC5000 22 - Steering System Removal and Installation Steering Column Covers Remove the 8 self-tapping screws (D) that secure the rear column cover (A) to the front column cover (B). Remove the 4 self-tapping screws (E) that secure the top column cover (C) to the front and rear covers.
Page 104: Steering Offset Box
Service Manual – SC5000 22 - Steering System Steering Offset Box Shut down the machine. Remove the rear and top steering column covers, as described in the “Steering Column Covers” on page 103. (It’s not necessary to remove the front cover.) Remove the four screws (A) that secure the display assembly to the top of the steering column.
Page 105 Service Manual – SC5000 22 - Steering System Remove the two screws (K, not visible) that secure the steering wheel to the clamping collar (M) of the steering box, and remove the wheel. 10. Remove the four screws (L) that secure the steering box to the steering column frame, and slide the box out of the U-joint to remove 11.
Page 106: 24 - Electrical System
Service Manual – SC5000 24 - Electrical System Functional Description The SC5000 machine is powered using six, 6-volt batteries connected in series, for a total Bat+ Terminal system nominal voltage of 36 volts. To protect 150 Amp the batteries from over discharge, the system Fuse is protected with a 150 amp fuse (F1) located on the battery positive main terminal.
Page 107: Low Voltage Cutout
Service Manual – SC5000 24 - Electrical System The main electrical bay is located below the operator’s seat, behind a removable panel. This contains the Main Machine Controller, the Drive Controller, and the Power Module. The K2 Relay provides high-energy power to the power module, Main and is controlled by the power module itself.
Page 108: Component Locations
Service Manual – SC5000 24 - Electrical System Component Locations Drive Controller Main Machine Controller KSI Relay User Interface Power Module Main Ground Lug K2 Power Relay...
Page 109: Troubleshooting
Service Manual – SC5000 24 - Electrical System Troubleshooting Battery Testing A battery problem is usually recognized by the machine operator as a decrease in the machine’s running time. This condition is usually caused by one or more “dead cells” in the battery system. There are 2 ways to find a dead cell: •...
Page 110: Battery Charger Error Codes
Service Manual – SC5000 24 - Electrical System Battery Charger Error Codes 8-E001 High battery voltage Description Battery voltage too high. When Monitored Setting The battery voltage is higher than the software setting. Conditions Charging Possible Causes Initial Action Troubleshooting Steps •...
Page 111 Service Manual – SC5000 24 - Electrical System 8-E003 Charge timed out Description When Monitored Setting Conditions Charging Possible Causes Initial Action Troubleshooting Steps • Charger output reduced due to high temperatures. Operate at lower ambient temperature. • Charger output reduced due to low AC voltages. Check AC voltage. •...
Page 112 Service Manual – SC5000 24 - Electrical System 8-E007 Bat. Ah limit reached Description Charge amp-hour Limit reached. Algorithm dependent. When Monitored Setting Conditions Charging Possible Causes Initial Action Troubleshooting Steps • Charger output reduced due to high temperatures. Operate at lower ambient temperature •...
Page 113 Service Manual – SC5000 24 - Electrical System 8-E012 Reverse polarity Description Battery connected with reverse polarity. When Monitored Setting Conditions Always Possible Causes Initial Action Troubleshooting Steps • Reverse the charger connections to the battery. 8-E013 Bat. not taking current Description The battery is not taking a charge.
Page 114 Service Manual – SC5000 24 - Electrical System 8-017 USB error Description USB mount/unmount error When Monitored Setting Conditions Updating Possible Causes Initial Action Troubleshooting Steps • Remove and re-insert the USB Drive. • Ensure the USB flash drive is properly formatted and is not corrupted. •...
Page 115 Service Manual – SC5000 24 - Electrical System 8-E021 Active algo not set Description High battery voltage while charging. Algorithm dependent – typically 2.8V/cell When Monitored Setting Conditions Charging Possible Causes Initial Action Troubleshooting Steps • When already full, some new batteries may exhibit this error. Cycle the batteries and see if it reoccurs. •...
Page 116 Service Manual – SC5000 24 - Electrical System 8-E023 AC voltage high Description High AC voltage error (>270VAC) When Monitored Setting Conditions Charging AC voltage is too high. Connect charger to an AC source that provides stable Possible Causes AC between 85 - 270 VAC / 45-65 Hz. This error will automatically clear once the condition has been corrected.
Page 117 Service Manual – SC5000 24 - Electrical System 8-026 USB Script Failed Description One or more USB script commands failed When Monitored Setting Conditions Updating Possible Causes Initial Action Troubleshooting Steps • Ensure the USB flash drive is properly formatted. •...
Page 118 Service Manual – SC5000 24 - Electrical System 8-E029 CAN bus error Description Cannot transmit on CAN bus When Monitored Setting Conditions Charging The CANBus has to be functional for this error to be reported to the Main Machine Possible Causes Controller.
Page 119 Service Manual – SC5000 24 - Electrical System 8-E037 CANdownload failure Description CAN Open reprogramming failed When Monitored Setting Conditions Bootup Possible Causes Initial Action Reboot the machine. Troubleshooting Steps 8-E038 Fan failure 8-E040 Fan voltage low Description The cooling fan on the side of the charger is not working properly. When Monitored Setting Conditions...
Page 120: Maintenance And Adjustment
Maintenance and Adjustment Battery Settings Onboard Battery Charger The Main Machine Controller uses the battery information to determine the appropriate low-voltage-cutout values for each specific battery type. It also communicates with the optional on-board battery charger to set the appropriate charging algorithm for the specific battery type. When the batteries are changed, the battery type should be set in the configuration menu.
Page 121: Removal And Installation
Service Manual – SC5000 Service Manual – SC5000 24 - Electrical System 24 - Electrical System Removal and Installation Batteries 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.
Page 122: Wiring Diagrams
Service Manual – SC5000 24 - Electrical System Wiring Diagrams Understanding the Features of the Electrical Circuit Diagram The electrical circuit diagram is sometimes referred to as a (V) TO 2A1 (B) TO 2A1 ladder diagram because it is historically rooted in a type of (AF) TO 2E1 schematic that resembled the rungs of a ladder.
Page 123: Device Labeling
Service Manual – SC5000 24 - Electrical System Device Labeling Device Numbers (Names): Each device is given its own unique identifier. The letter prefix identifies the type of device, such as “K” for a relay, “L” for a solenoid, “M” for motor, and “A” for a control module; just to name a few. Then each device within that class is given a unique number.
Page 124: Electrical Circuit Diagram
Service Manual – SC5000 24 - Electrical System Electrical Circuit Diagram Drawing 56117200, Rev. C Sheet 1, Contents...
Page 125: Sheet 2: Power/Charger/Main Controller Power
Service Manual – SC5000 24 - Electrical System Sheet 2: Power/Charger/Main Controller Power...
Page 126: Sheet 3: Controller Power
Service Manual – SC5000 24 - Electrical System Sheet 3: Controller Power...
Page 127: Sheet 4: Main Controller Functions
Service Manual – SC5000 24 - Electrical System Sheet 4: Main Controller Functions...
Page 128: Sheet 5: Power Module
Service Manual – SC5000 24 - Electrical System Sheet 5: Power Module W008A SERIAL PORT PROGRAMMER- POWER MODULE CONNECTOR...
Page 129: Sheet 6: Drive Module
Service Manual – SC5000 24 - Electrical System Sheet 6: Drive Module DRIVE MODULE PROGRAMMER-...
Page 130: Sheet 7: Vehicle Circuits
Service Manual – SC5000 24 - Electrical System Sheet 7: Vehicle Circuits...
Page 131: Sheet 8: Can Bus
Service Manual – SC5000 24 - Electrical System Sheet 8: CAN Bus J5-2 CAN(1) H J5-3 CAN(1) L J6-4 CAN(1) H J6-3 CAN(1) L J7-10 CAN(1) H J7-1 CAN(1) L...
Page 132: Condensed Electrical Circuit Diagram
Service Manual – SC5000 24 - Electrical System Condensed Electrical Circuit Diagram The Condensed Electrical Circuit Diagram is electrically the same as the engineering “Electrical Circuit Diagram” on page 124, but is condensed down into the more classical functional areas. Each of the functional area sheets were created as standalone diagrams, and therefore, circuit interconnects (Goto Jumps) are reference by a net-name (network name) instead of sheet coordinates (see the Legend for reference.)
Page 133: Sheet 2: Power Module
Service Manual – SC5000 24 - Electrical System Sheet 2: Power Module POWER MODULE J3-9 Power Module Contactor J3-2 Squeegee Actuator J6-14 GRN/RED K2 Bat+ Fuse, 10A. J6-13 − GRN/WHT Brush Motor M1 − Front Cylinderical Fuse, 30A. Deck Actuator RED/BRN J6-6 BRN/RED...
Page 134: Sheet 3: Drive Controller
Service Manual – SC5000 24 - Electrical System Sheet 3: Drive Controller Drive Controller B- Lug J5-22 J4-2 J4-1 B+ Lug EM BRAKE EM Brake 70 AMP E-Stop J5-6 BLU/YEL E-Stop MMC 3Ø Seat SW J5-4 BLU/GRY Seat SW MMC Thermistor Wheel Drive...
Page 135: Using The Wiring Diagram
Service Manual – SC5000 24 - Electrical System Using the Wiring Diagram The wiring diagram contains detailed information about the physical wiring within the machine. Every wire segment is listed. Every connector is listed. Even the hidden splice points between wires are listed. This information is useful for tracing a specific circuit as it passes through the machine.
Page 136: Wiring Diagram
Service Manual – SC5000 24 - Electrical System Modified Drawing 56117201, Rev. C Wiring Diagram Sheet 1 RED,1,W003 RED,16,W004 RED,16,W004A RED,6,W004B BLK,6,W201 BLK,6,W161 BLU,20,W175 GRY,20,W176 VIO,20,W173 GRY,18,W174 GRY,20,W192 GRY,20,W165 GRY,18,W167 GRY,20,W189 RED-VIO,20,W185 VIO-GRN,20,W188 VIO-ORN,20,W187 VIO-YEL,20,W186 YEL,18,W081 GRY-BLU,20,W082 GRY,18,W167 VIO,20,W168 RED,20,W166 RED,6,W200 BLK,6,W201 RED-BRN,10,W207B...
Page 137 Service Manual – SC5000 24 - Electrical System Sheet 2 YEL,18,W144 BLU-YEL,18,W145 GRN,18,W094B YEL,18,W093B YEL,18,W062 GRN-RED,16,W229 BRN-WHT,16,W230 RED-GRN,12,W208 GRN-GRY,12,W218 RED-GRN,12,W209 GRN-GRY,12,W219 YEL,18,W077 GRY-BLU,20,W078 BLU-YEL,20,W115 GRY-BLU,20,W120 BLU-GRY,16,W234 BLU-RED,16,W233 GRY,18,W068L BLU,18,W065L Headlight Harness BRN,20,W125 GRY,18,W068 GRY,18,W068A GRY,18,W126 BLK,16,RED_WIRE BLU,18,W065 BLU,18,W065A GRY,18,W068R BLU,18,W073 BRN-WHT,16,W222 BLU,18,W065R GRY-BLU,18,W074...
Page 138: Appendix A: Can Wiring
Service Manual – SC5000 24 - Electrical System Appendix A: CAN Wiring Can Diagnostic GRN, W034 YEL, W033...
Page 139: Appendix B: Ksi Wiring
Service Manual – SC5000 24 - Electrical System Appendix B: KSI Wiring BLK, W012 RED, W004A RED, W004 RED, W003 BLU, W016A...
Page 140: Harness Diagram
Service Manual – SC5000 24 - Electrical System Derived from Drawing 56117202, Rev. C Harness Diagram Sheet 1: Navigation Harness Diagram and To-From Tables Sheet 1: Navigation Derived from 65117202 Rev C Operator’s Front Position Chassis Area Lower Electrical Bay Drive Controller Scrub Area...
Page 141: Sheet 2: Lower Elec Bay, Front Chassis
Service Manual – SC5000 24 - Electrical System Sheet 2: Lower Elec. Bay, Front Chassis Harness Diagram and To-From Tables Sheet 2: Lower Electrical Bay Front Chassis Area Main Harness to Steering Column [132015-0115] PIN# WIRE COLOR TERM. NAME W130 4.J3-4 USB +5V W131...
Page 142: Sheet 3: Drive Controller, Traction Harness
Service Manual – SC5000 24 - Electrical System Sheet 3: Drive Controller, Traction Harness Harness Diagram and To-From Tables Sheet 3: Drive Controller Area Traction Harness Drive Controller [2-794617-4] PIN# WIRE COLOR TERM. NAME W165 5.SPL-51 Bat- (Pot Gnd) [794617-2] Drive Controller Brake W195 3.SPL-42...
Page 143: Sheet 4: Main Controller, Ksi Relay Areas
Service Manual – SC5000 24 - Electrical System Sheet 4: Main Controller, KSI Relay Areas Harness Diagram and To-From Tables Sheet 4: Main Controller Area KSI Relay Area [662014113322] Main Machine Controller PIN# WIRE COLOR TERM. NAME W115 BLU-YEL 7.X190-1 +5V Out W125 2.X168-2...
Page 144: Sheet 5: Power Module, Machine Power
Service Manual – SC5000 24 - Electrical System Sheet 5: Power Module, Machine Power Harness Diagram and To-From Tables Sheet 5: Power Module Machine Power Connections SPL-27 KSI (4) PIN# WIRE COLOR TERM. SPL-51 Bat- W016A 4.X28-1 PIN# WIRE COLOR TERM.
Page 145: Sheet 6: Lower Chassis And Scrub Deck Areas
Service Manual – SC5000 24 - Electrical System Sheet 6: Lower Chassis and Scrub Deck Areas Harness Diagram and To-From Tables Sheet 6: Lower Front Chassis Area Scrub Deck Area Operator’s Position Seat Switch [2-520183-2] PIN# WIRE COLOR TERM. NAME W021 5.SPL-27 KSI (4)
Page 146: Sheet 7: Rear Chassis, Recovery, Obc, Column Harness
Service Manual – SC5000 24 - Electrical System Sheet 7: Rear Chassis, Recovery, OBC, Column Harness Harness Diagram and To-From Tables Sheet 7: Recovery Area Rear Chassis Area Battery Charger Column Harness X204 [AT04-2P] Backup Alarm PIN# WIRE COLOR TERM. NAME W078 GRY-BLU...
Page 147: 3D Harness Connector Diagrams
Service Manual – SC5000 24 - Electrical System 3D Harness Connector Diagrams The following diagrams show the electrical harnesses and connectors within the machine. This can be used in conjunction with the “Electrical Connector Pin-Out Assignments” on page 153 to identify where connectors are located and how they appear.
Page 148: Power Distribution
Service Manual – SC5000 24 - Electrical System Power Distribution − − − − − Main Disconnect Unswitched Bat+ K2 Relay K2 switched Bat+...
Page 149: Main Harness, Electrical Bay
Service Manual – SC5000 24 - Electrical System Main Harness, Electrical Bay Seat Switch Reader X207 Fuse X225 Block X219 Main B+ K2 Power Main Gnd J1 Main Machine Controller ......153 J6 Power Module ..........156 J2 Main Machine Controller ......
Page 150: Column Harness And Main Harness-Front
Service Manual – SC5000 24 - Electrical System Column Harness and Main Harness-Front E-Stop X189 X168 J10 Main to Steering Column Interconnect ..157 P5 USB Connector ..........160 P1 Steering Column to Main Interconnect ..158 Side Sweep Motor ........
Page 151: Traction Harness
Service Manual – SC5000 24 - Electrical System Traction Harness X203 (Main Harness) X196 X226 X210 X218 X196 Traction to Main Interconnect ..... 160 X218 Wheel Brake .......... 165 X203 Main to Traction Interconnect ..... 161 X226 Drive Motor Temperature ....
Page 152: Main Harness, Rear
Service Manual – SC5000 24 - Electrical System Main Harness, Rear X151 X146 X156 X128 X126 X190 X204 J7 Battery Charger ........... 156 X126 Front Cylindrical Motor ......162 Squeegee Actuator ........ 161 X128 Right Disk Motor ........163 Wash Pump ...........
Page 153: Electrical Connector Pin-Out Assignments
Service Manual – SC5000 24 - Electrical System Electrical Connector Pin-Out Assignments The machine uses a wide variety of electrical connectors, which vary depending on amperage passed, moisture encountered, and number of conductors present. Diagnosing machine problems, frequently involves examining the physical condition of the connectors, as well as the electrical signals passing through them. The following tables list the individual connector pin-out assignments.
Page 154 Service Manual – SC5000 24 - Electrical System Main Machine Controller 662014113322 Pin# Wire Color Function W115 BLU-YEL Solution Level +5V W125 W108 BLU-WHT W030 W107 GRY-BLU W120 GRY-BLU Solution Level Return +12V Out Main Machine Controller 662012113322 Pin# Wire Color Function W133...
Page 155 Service Manual – SC5000 24 - Electrical System Drive Controller 2-794617-4 Pin# Wire Color Function W165 Potentiometer Gnd W195 CAN-1 H W196 CAN-1 L W163 BLU-GRY Seat Switch In W164 BLU-YEL E-Stop In W193 PNK-YEL Programmer Data W194 PNK-BLU Programmer Clock W166 Potentiometer +5V W198...
Page 156 Service Manual – SC5000 24 - Electrical System Power Module 776273-1 Pin# Wire Color Function W232 BRN-GRY Deck Actuator - W019 K2 Coil Out W245 CAN-1 L W244 CAN-1 H W240 Curtis Prog +15V W231F BRN-RED Deck Actuator + W242 PNK-YEL Curtis Prog RX W243...
Page 157 Service Manual – SC5000 24 - Electrical System Main to Steering Column Interconnect 132015-0115 Pin# Wire Color Function W130 USB +5V W131 WHT-BRN USB N W132 GRN-WHT USB P W133 USB Gnd W010A Frame Ground W107A BLU-YEL E-Stop W075 KSI (E-Stop) W058 YEL-VIO KSI (Trackclean)
Page 158 Service Manual – SC5000 24 - Electrical System Steering Column to Main Interconnect 132015-0074 Pin# Wire Color Function W130A USB +5V W131A WHT-BRN USB N W132A GRN-WHT USB P W133A USB Gnd W010B Frame Ground W107B BLU-YEL E-Stop W075A KSI (E-Stop) W058A YEL-VIO KSI (Trackclean)
Page 159 Service Manual – SC5000 24 - Electrical System TrackClean 132015-0075 Pin# Wire Color Function W064 W055 BAT+ 17 W058A YEL-VIO 23 W062A CAN-1 H 24 W063A CAN-1 L Blue Light ATM04-2P Pin# Wire Color Function W075B W076B...
Page 160 Service Manual – SC5000 24 - Electrical System USB Connector ATM04-4P Pin# Wire Color Function W130A W131A WHT-BRN USB+ W132A GRN-WHT USB- W133A Smart Key ATM04-2P Pin# Wire Color Function W105 GRY-BLK W104 BLU-PNK Smart Key to MMC X196 Traction to Main Interconnect ATM06-12S Pin# Wire...
Page 161 Service Manual – SC5000 24 - Electrical System X203 Main to Traction Interconnect ATM04-12P Pin# Wire Color Function W186 VIO-YEL Encoder U W187 VIO-ORN Encoder V W188 VIO-GRN Encoder W W185 RED-VIO +15V W189 I/O Ground W174 W173 Temperature W176 Brake- W175 Brake+...
Page 162 Service Manual – SC5000 24 - Electrical System Solution Solenoid AT06-2S Pin# Wire Color Function W145 BLU-YEL Solution Solenoid- W144 KSI +36V Headlight Harness ATM04-2P Pin# Wire Color Function W065 W068 Deck Actuator ATM04-2P Pin# Wire Color Function W231 BRN-RED W232 BRN-GRY Rear Cylindrical Motor...
Page 163 Service Manual – SC5000 24 - Electrical System X128 Right Disk Motor 19432-0013 Pin# Wire Color Function W216A BRN-GRY W206A RED-BRN K2 Power X146 Vacuum Motor 2 ATP04-2P Pin# Wire Color Function W209 RED-GRN W219 GRN-GRY X156 Vacuum Motor 1 ATP04-2P Pin# Wire Color...
Page 164 Service Manual – SC5000 24 - Electrical System X189 Foot Pedal ATM04-6P Pin# Wire Color Function W166 W168 Wiper W167 Ground X190 Solution Level Sensor ATM04-2P Pin# Wire Color Function W115 BLU-YEL W120 GRY-BLU Sensor Return X204 Backup Alarm AT04-2P Pin# Wire Color Function...
Page 165 Service Manual – SC5000 24 - Electrical System X210 Drive Motor Commutation ATM06-6S Pin# Wire Color Function W186A VIO-YEL Encoder U W187A VIO-ORG Encoder V W188A Encoder W W185A RED-VIO +15V Shield W189A I/O Ground X218 Wheel Brake ATM04-2P Pin# Wire Color Function GRN-...
Page 166 Service Manual – SC5000 24 - Electrical System X220 Fuse Block 2-794617-4 Pin# Wire Color Fuse Function W217AF BRN-GRY In: Left Disk Motor A W217A BRN-GRY 40A Out: Left Disk Motor W216AF BRN-GRY In: Right Disk Motor B W216A BRN-GRY 40A Out: Right Disk Motor W218F GRN-GRY...
Page 167: 30 - Solution System
Service Manual – SC5000 30 - Solution System Functional Description The SC5000 solution tank is incorporated Solution directly into the main body of the machine. A Tank series of 3 capacitive sensors serves as a level EcoFlex indicator for the amount of solution in the System tank.
Page 168: External Wash Options
Service Manual – SC5000 30 - Solution System The senor’s internal circuitry consumes only about 30 µA (10 µA per sensor body), but when the 2k Ω resistor is added, the consumption Amps jumps to approximately 2.5 mA per sensor body. This amperage is cumulative, such that as each sensor body detects capacitance, the MMC Actual 2k Ω...
Page 169: Ecoflex Option
Service Manual – SC5000 30 - Solution System EcoFlex Option Machines that have the EcoFlex option have on-board detergent mixing using a pump-driven detergent injection system. The detergent is stored in the removable detergent tank below the operator’s seat, which has a suction hose from the detergent pump.
Page 170: Plumbing Diagram
Service Manual – SC5000 30 - Solution System Plumbing Diagram EcoFlex Solution Bottle Tank EcoFlex Pump Connection for Optional Wash Kit EcoFlex Tubing Supply Hose Solution Solenoid Delivery to Disc Deck Brushes Filter Tank Drain Hose Shutoff Valve Delivery to Cyl. (connection Deck Brushes to tank at top...
Page 171: Troubleshooting
Service Manual – SC5000 30 - Solution System Troubleshooting Detergent Not Flowing Verify that the pickup tube in the Solenoid detergent bottle is below the liquid level of detergent, and is not blocked. Diaphragm Check the detergent tubing for cuts, damage, or loose connections, especially on the suction-side between the pump and bottle.
Page 172: Solution Level Indication Is Not Correct
Service Manual – SC5000 30 - Solution System Solution Level Indication is not Correct The solution level sensor is comprised of 3 independent sensor bodies working together. This is important to understand for the purposes of troubleshooting, because one sensor can fail and not affect the other 2. This could give unexpected results on a machine, such as displaying less fluid than what is actually in the tank, but no error is detected.
Page 173 Service Manual – SC5000 30 - Solution System Check the voltage between pins 1 and 2 of the X190 connector for 5 volts. • If 5 volts is not present, repair or replace the wiring between the controller and connector. •...
Page 174: Removal And Installation
Service Manual – SC5000 30 - Solution System Removal and Installation Solution Solenoid The solution solenoid is located in the center of the scrub deck on the rearward side of the deck. If the purpose for servicing the solenoid is to clean the valve seat, you may choose to separate the top and bottom while still in the machine, as described in step 5.
Page 175: Detergent Pump
Service Manual – SC5000 30 - Solution System Detergent Pump The detergent pump is located in the front right corner of the battery compartment, below the operator’s seat, the EcoFlex bottle, and the bottle support bracket. Remove the feed tube (A) from the detergent bottle (B), then lift the bottle out of the support bracket (C).
Page 176: Wash Hose Pump (Option)
Service Manual – SC5000 30 - Solution System Wash Hose Pump (Option) Although not necessary, it is easier to remove/install the wash pump (A) when the squeegee is removed and the scrub deck and squeegee lift are lowered. Lower the Squeegee and Scrub Deck Remove the squeegee assembly from the squeegee lift.
Page 177: Specifications
Service Manual – SC5000 30 - Solution System Specifications Parameter Range Solution Solenoid Resistance • 108 Ω Maximum Solution Flow • 6 L/Min, unrestricted...
Page 178: 34 - Scrub System, Disc
Service Manual – SC5000 34 - Scrub System, Disc Functional Description The disc deck is available in a 34-inch size. The deck uses two, gear-reduced, drive motors to drive the two brush or pad holder discs. The scrub deck is raised and lowered using a leadscrew actuator.
Page 179: Scrub Control
Service Manual – SC5000 34 - Scrub System, Disc Scrub Control Scrub pressure is controlled by monitoring the motor amperage from both brush motors. If the combined brush motor current is below its target amperage, the deck is lowered slightly to increase brush pressure. If the combined amperage is above the target amperage, the deck is raised slightly.
Page 180: Circuit Overview
Service Manual – SC5000 34 - Scrub System, Disc Circuit Overview The brush motors are powered from the power module. The power module controls the K2 relay, which provides battery+ power to the motors. The power module then applies PWM control to the negative side of the motor, including soft-start at startup.
Page 181: Maintenance And Adjustment
Service Manual – SC5000 34 - Scrub System, Disc Maintenance and Adjustment Lift Actuator Limit Adjustment The power module commands the actuator to raise or lower, but the actuator itself determines when it should stop moving. This is accomplished by two cam lobes and two micro switches (limit switches).
Page 182 Service Manual – SC5000 34 - Scrub System, Disc Adjusting Travel If the leadscrew travel needs to be adjusted, complete the steps below. Otherwise, skip down to Setting the Leadnut Position. Cam Lobe Remove the dust cap from the top of the actuator covering the adjustment cam.
Page 183: Removal And Installation
Service Manual – SC5000 34 - Scrub System, Disc Removal and Installation Scrub Deck Removing the scrub deck is a prerequisite to completing other procedures, such as servicing the brush motors. The procedure is the same for all scrub deck types. Optional: You may choose to place a sheet of cardboard under the scrub deck to make it easier to slide the deck in and out from under the machine.
Page 184: Deck Lift Actuator
Service Manual – SC5000 34 - Scrub System, Disc Deck Lift Actuator Scrub deck removed for clarity Remove the scrub brushes, so the deck can be lowered without pressing on the floor. From the service menu, lower the scrub deck, and then press the E-stop to lock out all motor functions, and then disconnect the main battery connector.
Page 185: Brush Motor Brushes
Service Manual – SC5000 34 - Scrub System, Disc Brush Motor Brushes Remove the Scrub Deck described on page 183. Remove the 3 screws (A) that secure the splash cover (B) to the top of the motor, and remove the cover. Make a witness mark (C) on the edge of the motor end bell to mark the rotational position of the end bell with respect to the...
Page 186 Service Manual – SC5000 34 - Scrub System, Disc When replacing the brush with a new one, note the following: • The brush wire is toward the top of the motor. • You may find it easier to use the brush wire itself to help you hold the screw on the end of your screw driver as you get the screw started in the threads.
Page 187: Specifications
Service Manual – SC5000 34 - Scrub System, Disc Specifications Parameter Range Brush Motor Amperage 31 amps max. Lift Actuator Amperage Special Tools Actuator Test Kit The actuator test kit (Pn 56407502) is used to manually control an actuator removed from the machine, but powered from a 36-volt battery.
Page 188: 34 - Scrub System, Cylindrical
Service Manual – SC5000 34 - Scrub System, Cylindrical Functional Description The cylindrical deck is optimal in environments where floor debris is to be expected during the cleaning process. The cylindrical deck consists of two counter rotating cylindrical brushes for scrubbing the floor, as well as channeling debris up and into a hopper.
Page 189: Scrub Control
Service Manual – SC5000 34 - Scrub System, Cylindrical Scrub Control Scrub pressure is controlled by monitoring the motor amperage from both brush motors. If the combined brush motor current is below its target amperage, the deck is lowered slightly to increase brush pressure. If the combined amperage is above the target amperage, the deck is raised slightly.
Page 190: Operational Mode Prerequisites
Service Manual – SC5000 34 - Scrub System, Cylindrical Operational Mode Prerequisites Before the main controller can activate any of the operational modes, it must first check that the appropriate prerequisites are met. • Scrub System Outputs – Brush Motors (M1 and M2) or Deck Actuator (M7) ◦...
Page 191: Maintenance And Adjustment
Service Manual – SC5000 34 - Scrub System, Cylindrical Maintenance and Adjustment Lift Actuator Limit Adjustment The power module commands the actuator to raise or lower, but the actuator itself determines when it should stop moving. This is accomplished by two cam lobes and two micro switches (limit switches).
Page 192 Service Manual – SC5000 34 - Scrub System, Cylindrical Adjusting Travel If the leadscrew travel needs to be adjusted, complete the steps below. Otherwise, skip down to Setting the Leadnut Position. Cam Lobe Remove the dust cap from the top of the actuator covering the adjustment cam.
Page 193: Removal And Installation
Service Manual – SC5000 34 - Scrub System, Cylindrical Removal and Installation Scrub Deck Removing the scrub deck is a prerequisite to completing other procedures, such as servicing the brush motors. If available, position a furniture dolly, mechanic’s creeper, or a sheet of cardboard below the scrub deck to make it easier to roll the deck out from under the machine.
Page 194 Service Manual – SC5000 34 - Scrub System, Cylindrical Remove the two link arm retaining clips (G) and pins (H) from the scrub deck. 10. Slide the deck toward the rear of the machine so the deck lift linkage will clear the brush motor, and then slide the deck out from the right side of the machine.
Page 195: Deck Lift Actuator
Service Manual – SC5000 34 - Scrub System, Cylindrical Deck Lift Actuator Remove the scrub brushes, so the deck can Scrub deck be lowered without pressing on the floor. removed for clarity From the service menu, lower the scrub deck, and then press the E-stop to lock out all motor functions, and then disconnect the main battery connector.
Page 196: Brush Drive Belt
Service Manual – SC5000 34 - Scrub System, Cylindrical Brush Drive Belt Brush Motor The initial procedure for removing the brush motor is the same as replacing the drive belt. Lowering the scrub deck is optional for replacing the belt, but it is required for removing the motor. Although not required for belt removal, you may choose to lower the scrub deck to provide better visibility of the belt drive system and access to the motor.
Page 197 Service Manual – SC5000 34 - Scrub System, Cylindrical Removing the Motor Disconnect the motor’s electrical connector. Remove the 4 screws (J) that secure the motor to the drive housing, and remove the motor. After the motor has been replaced, continue below to reinstall the drive belt.
Page 198: Brush Motor Brushes
Service Manual – SC5000 34 - Scrub System, Cylindrical Brush Motor Brushes Remove the Brush Motor described on page 196. Stand the motor up on a work bench. Mark the orientation of the motor end cap (C) and motor housing (D) with a line (A) between them .
Page 199 Service Manual – SC5000 34 - Scrub System, Cylindrical Gently retract the brush spring (G), and insert the new brush into the brush holder (H). Note that the brush wire is closest to the end cap body. 10. Release the brush spring and allow it to push the brush all the way in toward the bearing pocket (J) to verify that the spring is properly positioned.
Page 200: Specifications
Service Manual – SC5000 34 - Scrub System, Cylindrical Specifications Parameter Range Brush Motor Amperage 19 amps max. Lift Actuator Amperage Special Tools Actuator Test Kit The actuator test kit (Pn 56407502) is used to manually control an actuator removed from the machine, but powered from a 36-volt battery.
Page 201: 38 - Squeegee System
Service Manual – SC5000 38 - Squeegee System Functional Description The squeegee tool collects wastewater from the floor for the recovery system to lift the water into the recovery tank. The floor squeegee is wider than the path of the scrub deck to ensure collection of all wastewater from the perimeter of the scrubbing area.
Page 202: Squeegee
Service Manual – SC5000 38 - Squeegee System Squeegee The squeegee 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 front squeegee blade is intended to permit wastewater to enter the middle of the squeegee’s vacuum area, yet still maintain enough of a seal to not completely lose vacuum.
Page 203: Squeegee Height And Tilt Adjustment
Service Manual – SC5000 38 - Squeegee System Squeegee Height and Tilt Adjustment The squeegee height and tilt should be adjusted when the squeegee blades are replaced, or if the squeegee is not fully wiping the floor. Misadjustment symptoms include pooling in front of the squeegee or water streaks at the center or edges of the squeegee path.
Page 204: Squeegee Actuator Limit Adjustment
Service Manual – SC5000 38 - Squeegee System Squeegee Actuator Limit Adjustment The power module commands the actuator to raise or lower, but the actuator itself determines when it should stop moving. This is accomplished by two cam lobes and two micro switches (limit switches). The lower cam is not adjustable, so the lower limit is adjusted by rotating the leadscrew nut.
Page 205 Service Manual – SC5000 38 - Squeegee System Remove the dust cap from the top of the actuator covering the adjustment cam. Using a 1/2" socket, turn the adjustment cam: • Turn the cam only a couple of clicks at a time before rechecking the result. •...
Page 206: Removal And Installation
Service Manual – SC5000 38 - Squeegee System Removal and Installation Squeegee Lift Actuator Before turning off the machine,press the vacuum switch to lower the squeegee to the floor, then press the E-stop button to shut down all motors. With the E-stop active and without turning the machine off, disconnect the battery connector under the operator’s seat.
Page 207: Specifications
Service Manual – SC5000 38 - Squeegee System Specifications Parameter Range M6 Squeegee Actuator Motor No Load amps: 1.4 max. Full Load ams: 6.7 ±1.0 Special Tools Actuator Test Kit The actuator test kit (Pn 56407502) is used to manually control an actuator removed from the machine, but powered from a 36-volt battery.
Page 208: 40 - Recovery System
Service Manual – SC5000 40 - Recovery System Functional Description The recovery system extracts wastewater from the floor collected by the squeegee, and deposits it into the on-board recovery tank. Vacuum Motor and Recovery Tank The SC5000 machine has one standard vacuum motor, plus an optional second vacuum motor for higher vacuum draw.
Page 209: Vacuum Motor Control Circuit Overview
Service Manual – SC5000 40 - Recovery System Vacuum Motor Control Circuit Overview Power to the vacuum motor is controlled by the power module, which is commanded by the main controller. When the machine is enabled for operation, the power module activates the K2 power relay, that provides positive battery power to the vacuum motor, and other devices.
Page 210: Troubleshooting
Service Manual – SC5000 40 - Recovery System Troubleshooting 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 the vacuum motor inlet screen and clean any built-up debris from the screen. •...
Page 211: Vacuum Suction Test
Service Manual – SC5000 40 - Recovery System Vacuum Suction Test Use this procedure to verify that the vacuum system is performing within factory specifications. This procedure can also be used to isolate the cause of a vacuum problem between a clog or leak. It is a two-part procedure that verifies both static pressure and flow rate.
Page 212: Removal And Installation
Service Manual – SC5000 40 - Recovery System Removal and Installation Recovery Tank Removing the recovery tank is a prerequisite to performing other procedures on the machine, ro gain access to components otherwise not easily accessible. Drain the recovery tank. Raise the operator’s seat and disconnect the vacuum motor electrical connector.
Page 213 Service Manual – SC5000 40 - Recovery System Remove the 3 screws (E) and washers (F) that secure the vacuum retaining plate (G), and remove the plate. Lift the vacuum motor assembly (H) out of the recovery tank recess.
Page 214: Vacuum Motor Brushes
Service Manual – SC5000 40 - Recovery System Vacuum Motor Brushes Remove the Vacuum Motor described on page 212. Remove the two screws (A) that secure the motor cover to the motor, and remove the cover. Remove the two screws (C) that secure the contact strap (D), and remove the strap.
Page 215: Specifications
Service Manual – SC5000 40 - Recovery System Specifications Parameter Range Motor Amperage 18.1A at 100% Special Tools Vacuum Pressure Gauge 1-inch open hole adapter part number 56205281 Fabricated from PVC...
Page 216: 90 - Options And Accessories
Service Manual – SC5000 90 - Options and Accessories The SC5000 machine may be equipped with optional accessories depending on the needs of the owner. Some of these accessories don’t directly impact servicing the machine, but some may. So it is good to know what accessories you may encounter and how they impact the machine.
Page 217: Scrub-N-Vac
Service Manual – SC5000 90 - Options and Accessories Scrub-N-Vac MMC Setup Configuration Wash Hose Description The Wash Hose and Scrub-N-Vac are similar options, in that they both make use of the option pump. For this reason, only one of these options may be present on a machine at a time.
Page 218: Various Mechanical Kits
Service Manual – SC5000 90 - Options and Accessories Various Mechanical Kits MMC Setup None Description The following kits are mechanical in nature and do not pose a direct impact on serviceability beyond knowing they may be present. Battery Watering Kit This kit includes tubing and caps necessary to facilitate adding water to all flooded batteries simultaneously.

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