Clarke Clean Track® L24 56317170 Service Manual
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Clarke Clean Track® L24 56317170 Service Manual

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Clean Track
L24
®

Service Manual

Clarke Clean Track
L24, Model 56317170
®
5/12 Form No. 56043161

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Summary of Contents for Clarke Clean Track® L24 56317170

  • Page 1: Service Manual

    Clean Track ® Service Manual Clarke Clean Track L24, Model 56317170 ® 5/12 Form No. 56043161...

  • Page 2: Table Of Contents

    Contents Introduction ......................6 Parts and Service ....................6 Nameplate ......................6 Part Number .......................6 Serial Number ....................6 Transporting the Machine ...................6 Towing ........................6 Other Manuals and Information Sources for Your Machine ........ 7 Cautions and Warning Symbols ................. 7 Read all instructions before using..............7 General Safety Instructions ................7 Technical Specifications ..................9 General Maintenance ..................10...
  • Page 3 Scrub System ......................28 Functional Overview ..................28 Circuit Overview - Scrub Brush Motor M4 and M5 Run Function ..... 28 M3 - Scrub Brush Actuator Lift Motor Function ..........30 Scrub System Low-voltage Cut-out Function ........... 30 Scrub Brush Deck Removal ................31 Scrub Brush Motor Removal ................33 Scrub Brush Belt Replacement ................33 Scrub Brush System Maintenance ..............
  • Page 4 Electrical System ....................57 Batteries ......................57 If your machine shipped with batteries installed, do the following: ....57 If your machine shipped without batteries installed do the following: .... 57 When Servicing Batteries ................57 Specific Wet Cell Battery Information ............... 58 Wet Cell Battery Specifications ..............58 Wet Cell Battery Charger Specifications ............
  • Page 5 Service Test Mode ....................73 To Enter the Service Test Mode ..............73 Panel Indicators – Service Test Mode ............73 To Run the Wheel Drive Motor ..............74 To Switch the Solution System On and Off ........... 74 To Lower and Raise the Scrub Deck ............. 74 To Switch the Vacuum Motors On and Off ............

  • Page 6: Introduction

    Repairs should be performed by your Authorized Clarke Center, that employs factory trained service personnel and maintains an inventory of original replacement parts and accessories. Call the Clarke Dealer named below for repair parts or service. Please specify the Model Number (same as the Part Number) and Serial Number when discussing your machine.

  • Page 7: Other Manuals And Information Sources For Your Machine

    ™ • EzParts service / parts CD-ROM Cautions and Warning Symbols Clarke uses the symbols below to signal potentially dangerous conditions. Read this information carefully and take the necessary steps to protect personnel and property. Danger! Is used to warn of immediate hazards that will cause severe personal injury or death.

  • Page 8: Save These Instructions

    • This machine is not approved for use on public paths or roads. • This machine is not suitable for picking up hazardous dust. • Use care when using scarifier discs and grinding stones. Clarke will not be held responsible for any damage to floor surfaces caused by scarifiers or grinding stones.

  • Page 9: Technical Specifications

    Technical Specifications Voltage 24 Volt Power Source (4) 6 volt batteries (wet acid and gel cell available) Onboard Battery Charger 24 volt, 25 amp Wet/Gel Compatible Solution Control Precision-flow electric pump/solenoid valves Solution Tank 20 gal. [76 L] Recovery Tank 20 gal.

  • Page 10: General Maintenance

    Note: See the individual machine system sections for maintenance information. * Have Clarke check the vacuum motor carbon brushes once a year or after 300 operating hours. Check the brush motor and drive motor carbon brushes every 500 hours or once a year.

  • Page 11: Batteries And Chargers

    Batteries and Chargers Attention: See the Electrical System section for battery installation, battery maintenance and charger system requirements. Lubricating the Machine Lubricate the following components: Refer to Figure 1. • Once a month lubricate the General Figure 1 Pivot Points for the Brush Linkage (A).
  • Page 12 ® ® Clarke Clean Track PM Checklist Defect Codes Customer needs adjustment binding Address dirty or contaminated damaged, bent or torn City leaks missing Model Serial Hours worn out Does Operational Inspection Items Defect Codes (circle) Work Drive Paddle Operation (check for fwd/rev drive and any neutral creep)

  • Page 13: Know Your Machine

    Know Your Machine Major Components As you read this manual, you will occasionally run across a bold number or letter in parentheses - example: (2). These numbers refer to an item shown on this page unless otherwise noted. Refer back to this page whenever necessary to pinpoint the location of an item mentioned in the text.

  • Page 14: Major Components (Continued)

    Major Components (continued) Control Panel Rear Caster Operator Control Handle Accessory Port Drive Paddle Solution Filter Speed Control Knob Debris Hopper Solution Drain Hose / Level Indicator Vacuum Recovery Hose 10-amp Control Circuit Circuit Breaker Solution Shutoff Valve 30-amp Drive Motor Circuit Breaker Recovery Drain Hose Cap Recovery Tank Drain Hose Figure 3...

  • Page 15: Control Panel

    Control Panel Key Switch (Main Power) D6 Restoration Extract Mode Indicator Detergent System Switch D7 Fast Pre-spray Mode Solution/Pre-spray Switch D8 Heavy Pre-spray Mode Display Panel D9 Battery Low Indicator D1 Detergent (Chemical Mixing) System Indicator Vacuum Switch D2 Hour Meter/Battery Indicator Speed Control Fault Code Indicator D3 Fault Indicator Wand Switch...

  • Page 16: Control Panel Switch Functions

    Control Panel Switch Functions Key Switch (A) Main power switch Detergent System Switch (B) This switch controls the on-board chemical mixing (detergent) system. • Pressing and releasing this switch while the solution system is active will toggle the detergent system on and off. • The Chemical Mixing System Indicator (D1) informs the operator when the detergent bottle is low.
  • Page 17 If the scrub system is activated in the maintenance or restoration extraction mode, pressing this switch will cause the following to occur: • The solution system will toggle between disabled and enabled. The solution flow will only turn on when the throttle is moved from the neutral position in the forward direction.
  • Page 18 Scrub ON Switch (J) If the scrub system is off or in the restoration extract mode, pressing this switch will cause the machine to enter maintenance extract mode. The following will occur: • The scrub system will be enabled with the system configured for the maintenance mode, and the scrub deck will be lowered.

  • Page 19: Control Panel Indicators

    Control Panel Indicators Chemical Mixing System Indicator (D1) The machine has a Chemical Mixing System Indicator in the lower left corner of the display. When the detergent (chemical) system is enabled, the indicator will show a detergent bottle icon. When the detergent system is disabled, the detergent bottle icon will have a cross through it.

  • Page 20: General Guidelines For Control Panel Indicators

    Fault Indicator (D3) If an electrical fault occurs, the Fault Indicator will display the associated error code immediately. The error code number will be displayed with a wrench icon right of the battery condition indicator. Refer to the Error Code section for descriptions.

  • Page 21: Solution System

    Solution System Functional Overview The Clean Track L24 has a solution tank capacity of 20 gallons (76 liters) with a right rear tank fill opening. A flexible clear hose on the side of the solution tank indicates the solution level, and is used to drain the tank for system maintenance.

  • Page 22: Circuit Overview - Solution Auto Mode (Solenoid Valve Circuit)

    Note: See the Control Panel Switch Functions sections in this manual for a complete explanation of the solution operation modes. During normal machine scrubbing the solution system’s Auto Mode is selected and works in conjunction with the wheel drive speed controller and the (A1) main controller’s scrub system outputs to turn solenoid valves L1 and L2 and solution pump M1 on and off.
  • Page 23 - (Negative) circuit input starts with: • Battery negative ground inputs at the A1 Control Board and A2 Speed Control Ground terminals. • The A1 control board solution button enabled. • A negative voltage output from the A2 speed controller’s (pin #6) RED/BLK wire to the A1 control board RED/BLK wire (terminal J1-5).

  • Page 24: Solution System Maintenance

    Solution System Maintenance Solution Tank 1. Empty the solution tank weekly. 2. 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 flush the tank with clean water. Solution Filter See Figure 4.

  • Page 25: Symptom One - No Solution Flow While In The Scrub Auto Solution Mode

    Symptom One - No Solution Flow While in the Scrub Auto Solution Mode Note: Activate the Service Test Mode Program. See the optional program section for instructions. All testing will be performed in the Service Test Mode Program. While in the Remove the solution feed hoses from solution solenoid Service Test...

  • Page 26: Symptom Two - Solution Pump Will Not Operate

    Symptom Two - Solution Pump Will Not Operate Note: Activate the Service Test Mode Program. See the optional program section for instructions. All testing will be performed in the Service Test Mode Program. Check for (+) 24V to Bat.(-) Disconnect the from the red main harness pump wire Repair wiring...

  • Page 27: Solenoid Valve Removal

    Solenoid Valve Removal 1. Drain the solution tank or turn the solution filter ball valve to the off position to prevent solution loss. 2. Lower the deck and disconnect the battery supply to the machine. 3. Remove the front nose cone from the machine by firmly grasping the lower part and lifting straight up. 4.

  • Page 28: Scrub System

    Scrub System Functional Overview The Clean Track L24 uses two cylindrical brushes that counter-rotate to sweep up light debris and scrub at the same ® time. Each scrub brush is powered on opposing ends by 1/2 HP permanent magnet motors attached to separate poly-V belt/pulley drives.
  • Page 29 Figure 6 Fuse, 150 A Onboard Battery Charger A1 Control Board Interlock J2-4 BRN/WHT B+ Unswitched BRN/WHT J2-8 B- Switched Circuit Breaker, 10 A. Switch, SPST Key VIO/YEL Motor, Brush Actuator WHT/GRN VIO/BLK J1-1 Brush Contactor Coil, Brush Motor Contactor J2-5 Ground J2-6...

  • Page 30: M3 - Scrub Brush Actuator Lift Motor Function

    M3 - Scrub Brush Actuator Lift Motor Function The Scrub Brush Actuator continuously raises and lowers the scrub deck as needed to maintain optimum brush contact with the floor surface. The Scrub Brush Actuator lift motor is controlled by the amount current drawn by the scrub brush motors as follows: • If the control board senses that the brush motors are drawing too much current, the Scrub Brush Actuator lift motor raises the scrub deck until the brush motor current draw is within the acceptable range.

  • Page 31: Scrub Brush Deck Removal

    Scrub Brush Deck Removal 1. Turn the Key Switch on and lower the scrub deck. 2. Lift up and remove the cover and nose cone from the front of the machine. 3. Disconnect the electrical connector from the deck actuator motor to prevent the deck from rising once the Key Switch is turned off.
  • Page 32 13. Remove the Clips holding the Gas Springs to the Actuator Yoke, then remove the actuator assembly from the machine. Clip Spring 14. Disconnect the two Pivot Links from the deck weldment. Note that Left-hand there is a Bushing in the Left-hand Pivot Link and a Flange Bearing in Pivot Link the Right-hand Pivot Link (as viewed from the operator position).

  • Page 33: Scrub Brush Motor Removal

    16. Remove the cotter hair pins and ring pins that attach the scrub deck to the machine chassis linkage arms, then rotate the arms out of the way. 17. Carefully slide the deck toward the front of the machine. Note that you may need to loosen the fasteners holding the two Pivot Links together to free the deck weldment from the Pivot Links.

  • Page 34: Scrub Brush System Maintenance

    Scrub Brush System Maintenance The scrubbing system must be serviced at regular intervals to maintain good scrubbing performance. Follow the maintenance steps listed below: Daily Maintenance Weekly Maintenance Monthly Maintenance Rinse and clean any built-up Clean the drain holes in the solution delivery trough on Inspect the scrub brush debris from the debris hopper top of the scrub deck.
  • Page 35 8. Remove the Cotter Hair Pin from one side of the Actuator Pin, then remove the Actuator Pin and the two Spacers from the deck weldment and Actuator Tube. Cotter Hair Pin (2) Spacer (2) Actuator Service Tip: It is important that the actuator motor is not run or the actuator is not rotated while it is disconnected from the deck or chassis mounts.
  • Page 36 Scrub Brush Removal and Installation 1. Make sure the deck is raised, then turn the Key Switch off and disconnect the battery pack. 2. See Figure 8. Loosen the black knobs (one on each side) that secure the removable bearing Idler Support Plate Assembly (9) to the brush housing, then pull the plates down and out to remove.

  • Page 37: Recovery System

    Recovery System Functional Overview See Figure 9. Dirt and water are lifted off the floor into the recovery tank by airflow created by two three-stage 24V Vacuum Motors. Recovery Tank Cover Figure 9 Fan Inlet Screen (2) Drainhose Recovery Tank Float Switch Vacuum...

  • Page 38: Vacuum Motor Control Circuit Overview (Auto Mode)

    The wastewater and air enter the vacuum system through the extraction/vacuum shoe assemblies. The air and wastewater move through the vacuum hoses at high speed until they reach the recovery tank. Once the air and wastewater reach the recovery tank, the air slows down because of the increased volume (large size) of tank.
  • Page 39 Figure 10 Fuse, 150 A Onboard Battery Charger A1 Control Board Interlock J2-4 BRN/WHT B+ Unswitched BRN/WHT J2-8 B- Switched Circuit Breaker, 10 A. Switch, SPST Key BLU/RED J2-1 Vacuum Contactor Coil, Vacuum Motor Contactor J2-5 ORN/RED J1-10 Ground Aux. Vacuum Contactor Coil, Aux.

  • Page 40: Vacuum / Recovery System Service Maintenance Checklist

    Vacuum / Recovery System 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 float switch. Inspect the vacuum motor inlet screens and clean any built-up debris from the screens.

  • Page 41: Maintenance Of Recovery Tank Float Switch

    Maintenance of Recovery Tank Float Switch See Figure 11. If the recovery tank float switch becomes dirty it can impair its operation. A dirty vacuum shutoff switch can cause the vacuum motors to not function at all, or not shut off when the tank is full. If daily rinsing of the recovery tank is not adequate to keep the switch clean, you may need to remove the float arm for cleaning.

  • Page 42: Maintenance Of The Vacuum Motor Inlet Screens

    Maintenance of the Vacuum Motor Inlet Screens Figure 12 The two Vacuum Motor Inlet Screens (4) should be cleaned on a daily basis. DO NOT run water down the screens in an attempt to clean them. If you do this you will be running water directly into the vacuum motors.

  • Page 43: Vacuum Shoe Maintenance

    Vacuum Shoe Maintenance Check the vacuum shoes daily. Remove any built-up string, hair or carpet fibers. To remove: 1. Press the red Scrub OFF Switch (H). Turn the master Key Switch (A) off. 2. Remove the Debris Hopper (29). Note: Remove the left side shoe first to allow clearance for the right side shoe to slide out. 3.

  • Page 44: Vacuum Motor Removal

    Vacuum Motor Removal 1. Drain the recovery tank using the drain hose. 2. Turn the key off and disconnect the battery pack. 3. See Figure 14. Swing open the Recovery Tank and remove the Vacuum Cover (seven screws and washers). 4.
  • Page 45 Figure 14 Recovery Tank Cover Recovery Lid Gasket Fan Inlet Screen Drainhose Recovery Tank Float Switch Vacuum Vacuum Hose Motor Gasket Assembly Vacuum Motor Vacuum Duct Gasket Vacuum Duct Gasket Vacuum Cover Plate Gasket Vacuum Cover Form No. 56043161 - Clean Track L24 - 45 ®...

  • Page 46: Caster Wheel Removal

    Caster Wheel Removal Warning! Disconnect the battery pack connector before servicing machine. Warning! Never work under machine without safety stands or blocking to support the machine. 1. Drain both the solution and recovery tanks. 2. Have the scrub deck in the up (stored) position with the scrub brushes installed. 3.

  • Page 47: Wheel Drive System

    Wheel Drive System General Functional Overview See Figures 16 and 17. A 300-watt (.4 HP) permanent magnet (24V) motor transaxle (M8) is used for the wheel drive on all machines. A Curtis PMC solid-state speed controller (A2) regulates the variable speed and Forward/Reverse wheel drive motor functions.

  • Page 48: Drive Motor System Function

    Drive Motor System Function See Figures 17 and 18. With the Key Switch S1 closed, the BRN wire inputs 24V to the A2 speed controller (pin 5-KSI) to make its internal control circuits operational (powering it up). The CB2 circuit breaker (30-Amp) supplies the positive load circuit voltage input to the B+ controller terminal (WHT/YEL wire).

  • Page 49: A1 Speed Control Pin Connections

    A1 Speed Control Pin Connections R2 Voltage Values R1 Voltage Values 0V -= Minimum Speed 2.5V - 5V Forward 5V = Maximum Speed 0 - 2.5V Reverse Figure 18 WHEEL DRIVE SYSTEM R1 Throttle 5K Ohms A1 Speed Control Pin Connection POT HIGH STATUS BRAKE...

  • Page 50: Wheel Drive Troubleshooting Guide

    Wheel Drive Troubleshooting Guide Problem Possible Cause • Wheel Drive Motor Circuit Breaker (CB2) tripped - reset 30A circuit breaker • Control Circuit Circuit Breaker (CB1) tripped - reset Wheel drive motor will not run in forward and reverse. circuit breaker • Defective Wheel Drive Motor - replace motor • Defective Throttle Potentiometer (R1) - replace * • Test the Forward and Reverse (R1) wiring outputs (pins...

  • Page 51: Drive Motor Transaxle Removal

    Drive Motor Transaxle Removal Warning! Disconnect the battery pack before servicing machine. Warning! Never work under machine without safety stands or blocking to support the machine. 1. Drain both the solution and recovery tanks. 2. Remove the Scrub deck by following the Scrub Brush Deck Removal instructions in this manual. 3.

  • Page 52: Drive Motor Transaxle Removal (Continued)

    Drive Motor Transaxle Removal (continued) 1. See Figure 20. Jack the front of the machine from this location until the drive wheels are approximately 1” off the ground. 2. Remove the eight Locknuts (A) and then remove the two Drive Wheels (B) from the transaxle. 3.

  • Page 53: Drive Wheel Removal

    Drive Wheel Removal Warning! Disconnect the battery pack before servicing machine. Warning! Never work under machine without safety stands or blocking to support the machine. 1. Place wood blocking in front and rear of the opposite drive wheel that you are removing to prevent the machine from rolling.

  • Page 54: Directional/Throttle Potentiometer (R1)

    5K Directional/Throttle Potentiometer (R1) Warning! Disconnect the battery pack before servicing machine. Testing the 5K Directional/Throttle Potentiometer R1 Note: The potentiometer (pot) doesn’t have to be removed from its housing mount to test. 1. See Figure 22. Remove the front Drive Paddle Cover (G) from the Rear Housing (H) held together with four Screws (I) .

  • Page 55: Removing The R1 5K Potentiometer

    Figure 24 Removing the R1 5K Potentiometer 1. See Figure 24. Loosen the pot shaft anchor nut and spin it to the end of the shaft. 2. Back out the Screw (J) from the pot Fork (K). 3. Maneuver the pot (R1) out from its mounting bracket hole and separate the Fork (K) from the shaft end.

  • Page 56: 100K Potentiometer (R2)

    100K Potentiometer (R2) Warning! Disconnect the battery pack before servicing machine. Note: The potentiometer (pot) doesn’t have to be removed from the drive paddle cover to test. Test Procedure 1. See Figure 22. Remove the front drive paddle Cover (G) from the Rear Housing (H) held together with four Screws (I).

  • Page 57: Electrical System

    If your machine shipped without batteries installed do the following: • Consult your Authorized Clarke dealer for recommended batteries. • Install the batteries by following the instructions below. • DO NOT install two 12-volt batteries in your machine. This affects the stability of the machine.

  • Page 58: Specific Wet Cell Battery Information

    • Use a combination of multiple 2-volt cell units to construct a 24-volt DC battery pack system. • The battery pack capacity recommended by Clarke is a 238 AH @ 20 Hour Rate deep cycle battery system. Note: The battery pack must fit the battery compartment as listed in the Technical Specifications.

  • Page 59: Description Of The Low-Voltage Cutout Feature

    Description of the Low-voltage Cutout Feature The Clean Track L24 is equipped with a low-voltage cutout feature to prevent over-discharging of the batteries. When ® a machine’s battery pack voltage falls below a specifically defined threshold (voltage setting), the scrub system is automatically shut down. This cutout level is adjustable. The standard lead acid battery (wet cell) setting is 1.72V per cell. The alternate maintenance-free battery (gel cell) setting is 1.81V per cell. The standard setting is factory selected and should be used unless the battery manufacturer specifies the higher cutout voltage. Service Note: On all the 24V machines, a minimum recharge voltage of 2.13 volts per cell must be reached to allow the scrub brush and solution system to (reset) function again. A 24V battery pack must increase to a 25.6-volt minimum. Description of the Battery Condition Indicators The Battery Indicator (D2) will give an indication of the state of charge of the batteries.

  • Page 60: Charging Wet Batteries

    Charging Wet Batteries Charge the batteries each time the machine is used, or when the Battery Indicator (D2) is reading less than full. Warning! • Do not fill the batteries before charging. • Charge batteries in a well-ventilated area. • Do not smoke while charging the batteries. When Servicing Wet Batteries • Remove all jewelry. • Do not smoke. • Wear safety glasses, rubber gloves and a rubber apron. • Work in a well-ventilated area. • Do not allow tools to touch more than one battery terminal at a time.

  • Page 61: Charging Gel (Vrla) Batteries

    Caution! Acid can spill onto the floor if the batteries are overfilled. 3. Tighten the vent caps. 4. Wash the tops of the batteries with a solution of baking soda and water (2 tablespoons of baking soda to 1 liter of water). Charging Gel (VRLA) Batteries Charge the batteries each time the machine is used, or when the Battery Indicator (D2) is reading less than full. Warning! • Charge batteries in a well-ventilated area.

  • Page 62: If Your Machine Shipped Without An Onboard Battery Charger, Do The Following

    If your machine shipped without an onboard battery charger, do the following: 1. Disconnect the batteries from the machine and push the connector from the charger into the Battery Pack Connector (17). 2. Follow the instructions on the battery charger. Service Note: Make sure you plug the battery charger into the connector with the handle attached to it.

  • Page 63: Actuator Drive Nut Adjustment

    Percent of Charge Specific Gravity 100% (full charge) 1.265 1.225 1.190 1.155 0% (discharged) 1.120 2. Use a voltmeter to check the voltage of each battery with the scrub and drive motors running. The battery with the dead cell will read 1 or 2 volts lower than the other batteries in the system. If the batteries in the machine are more than one year old, it’s usually best to replace the whole set, rather than replacing just one battery.

  • Page 64: Adjusting The Drive Nut On The Scrub Brush Lift Actuator

    Adjusting the Drive Nut on the Scrub Brush Lift Actuator Figure 28 1. See Figures 28 and 29. On a new scrub lift actuator motor, remove (spin-off) the Drive Nut (B) and slide on the Spring Housing Guide (A). 2. Install the short compression Spring (C) onto the actuator (lead screw) shaft.
  • Page 65 Service Tip: See Figure 29. Note the correct orientation of the Spring Housing (D) when installing the complete motor assembly. Run the spring housing assembly to the IN (retracted) position for before you install it in the machine. Figure 29 Form No. 56043161 - Clean Track L24 - 65 ®...

  • Page 66: Curtis Controller Diagnostics

    Curtis Controller Diagnostics Diagnostics Method A - LED Panel and Speed Control Fault Code Indicator Diagnostics Method A uses the machine’s control display LED panel and Speed Control Fault Code Indicator (F). The Curtis 1210- (24V) speed control will output a fault code if there is a problem associated with the speed control and wheel drive system. See Figure 30. If a speed control fault occurs, the display LED panel (D) will indicate 03.

  • Page 67: Diagnostic History

    Figure 30 Fault Indicator Speed Control Fault Indicator (F) Diagnostic History The handheld programmer can be used to access the controller’s diagnostic history file. Connect the programmer, press the key, then while continuing to hold the key, press the key. The MORE INFO MORE INFO DIAGNOSTICS programmer will read out all the faults that the controller has experienced since the last time the diagnostic history file was cleared. The faults may be intermittent faults, faults caused by loose wires or faults caused by operator errors. Faults such as HPD or over-temperature may be caused by operator habits or by overloading. After a problem has been diagnosed and corrected, clearing the diagnostic history file is advisable. This allows the controller to accumulate a new file of faults. By checking the new diagnostic history file at a later date, you can readily determine whether the problem was indeed completely fixed.
  • Page 68 Status LED Fault Codes (Table 1) Status Light Code Display Explanation Possible Cause 1. Temperature >92°C or < -25°C. 2. Excessive load on vehicle 3. Operation in extreme environments. over-/under-temperature cutback 4. Electromagnetic brake not releasing. 1. Throttle input wire open or shorted 2. Throttle pot defective. 0 00 throttle fault 3.

  • Page 69: Speed Control Programming Options

    Speed Control Programming Options Following is a list of the speed control parameters that can be adjusted using a Curtis hand held programmers: • M1 MAX SPEED – Transport/Scrub speed maximum limit (% of full throttle) • M2 MAX SPEED – Not applicable • M1 MIN SPEED – Transport/Scrub speed maximum limit with the speed limit pot in minimum position (% of full throttle limited by speed limit pot) • M2 MIN SPEED –...

  • Page 70: Programming Vehicle Speed Changes

    Note: Before pressing the diagnostics key, wait until model # screen appears, if the throttle is activated prior to this screen appearing the controller will shut down. • If there is a problem, the LED will flash a diagnostic code and the programmer will display a diagnostic message. If you are conducting the checkout without a programmer, look up the LED diagnostic code in the Curtis Controller Diagnostics section of this chapter and Status LED Fault Codes (Table 1). • When the problem has been corrected, it may be necessary to cycle the key or seat switch to clear the fault code. 4. Move the drive paddle to operate the throttle. The motor should begin to turn in the selected direction. If it does not, verify the wiring to the controller, and the motor. The motor should run proportionally faster with increasing throttle. If not, refer to the Curtis Controller Diagnostics section of this chapter and Status LED Fault Codes (Table 1).

  • Page 71: Troubleshooting Guide

    The secondary function of the main control board is to detect any system failures and display an error code on the display LED panel, or store it in the main control board’s recall memory mode. The error code(s) are used to help the service person determine the fault and to quickly guide in repairing a specific system malfunction. Note: See the Troubleshooting Guide below for further information. An additional special feature of the main control board is to change program settings for a set of specific machine functions. See the Main Control Programming Options section in this manual for further information. Troubleshooting Guide Any error codes detected by main control board will be displayed on the LED display panel as they occur.
  • Page 72 Display Fault Description Troubleshooting Action Code 1. Check for wiring problems (short) on the coil circuit and repair wiring. Brush motor contactor coil K1 2. Check the coil resistance. The nominal resistance is 53 ohms for White Rogers overload. and 100 ohms for Ametek. If resistance is below 45 Ohms, replace the solenoid. 1.

  • Page 73: Service Test Mode

    *Short Circuit definition: • A short circuit is a parallel path of very low resistance, often caused accidentally. • With low resistance there is an excessive amount of current. • The excessive current will either melt the wires or open a fusible link. Service Test Mode To assist in the troubleshooting and servicing of the electrical system and related components, a special Service Test Mode has been incorporated that allows independent control of the various outputs and monitoring of the various inputs. The Service Test Mode overrides the normal operational protocols.

  • Page 74: To Run The Wheel Drive Motor

    To Run the Wheel Drive Motor The Drive Paddle (20) controls the wheel drive motor in the Service Test Mode. • With the Drive Paddle in the neutral position, the machine will remain stationary. The display will read SPD:OFF • Pressing the Drive Paddle forward will move the machine forward. The display will read SPD:FOR • Pulling the Drive Paddle backward will move the machine in reverse. The display will read SPD:REV Indicator Function...

  • Page 75: To Switch The Vacuum Motors On And Off

    To Switch the Vacuum Motors On and Off The Vacuum Switch (E) controls the vacuum motors in the Service Test Mode. • Pressing the Vacuum Switch when both vacuum motors are off switches on the main vacuum motor. The display will read VAC:1 • Pressing the Vacuum Switch a second time shuts off the main vacuum motor.

  • Page 76: To Switch The On-Board Chemical Mixing System On And Off

    To Switch the On-board Chemical Mixing System On and Off The Detergent System switch (B) controls the chemical (detergent) pump in the Service Test Mode. • Pressing the Detergent System switch switches on the chemical pump. The display will read CPUMP:ON • Pressing the Detergent System switch a second time switches off the chemical pump.
  • Page 77 You can select the scrub motor upper and lower current limits to compensate for different brush and/or carpet types. The current limit settings range from 0 to 9, with 0 being the least load/current draw and 9 being the greatest. To select the current limit range for a particular scrub mode: 1. Turn the Key Switch (A) to the off position. 2. Press and hold the button combo for the scrub mode you wish to change as listed in the table below. Scrub Setting Factory Default Button Combo for Programming Programming Indicator...

  • Page 78: Restoring The Scrub Pressure Limits To The Factory Default Settings

    Restoring the Scrub Pressure Limits to the Factory Default Settings Factory Default: Maintenance Mode – 9, Restoration Mode – 9, Pre-spray Mode – 9 To restore the scrub pressure limits to the default setting, perform the following steps: 1. Turn the Key Switch (A) to the off position. 2. Press and hold the Scrub ON Switch (J). 3. While holding the Scrub ON Switch, turn the Key Switch to the on position. 4. Continue to hold the Scrub ON Switch until the scrub off indicator is green and the display shows a brush icon and a key icon.

  • Page 79: Displaying The Control Unit Revision Level

    5. Release both switches. The display will now show a wrench icon or a wrench icon with a cross through it. 6. Press and release the Scrub ON Switch (J) to select between the wrench icon for fault detection enabled, or the wrench icon with a cross through it for fault detection disabled. 7.

  • Page 80: Detergent Dilution Ratio Selection

    Detergent Dilution Ratio Selection Factory Default: Chemical System Default: Off, Detergent Dilution Ratio: 1:128, Ratio Offset: 0 When the chemical mixing system senses that a ratio is not picked on the detergent bottle, it defaults to a predetermined value. In some cases this value may need to be changed for different detergents. Also, the chemical system defaults to inactive during normal scrubbing operations. Also, it may be determined that the chemical system should pump more or less detergent for a given ratio setting. These the settings can be changed by following this procedure: 1. Turn the Key Switch (A) to the off position. 2. Press and hold the Detergent System Switch (B). 3.
  • Page 81 8. When the correct setting is selected, press the Scrub OFF Switch to save it. 9. The display will now show a key icon to indicate the procedure is done. Turn the main power key switch to the off position. 10. The new setting will be saved and will remain in effect until it is changed again. Form No.

  • Page 82: Electrical Wiring Diagram/Schematic

    Electrical Wiring Diagram/Schematic CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK-ADVANCE, INC., PLYMOUTH, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE REPRO- DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND RECIPIENT AGREES TO RETURN IT UPON REQUEST.

  • Page 83: Electrical Ladder Diagram

    CONFIDENTIAL THIS DRAWING AND THE DESIGN REPRESENTED HEREON IS THE PROPERTY OF NILFISK-ADVANCE PLYMOUTH, MINNESOTA AND IT HAS BEEN ISSUED WITH THE UNDERSTANDING THAT IT WILL NOT BE DUCED NOR COPIED NOR USED FOR ANY PURPOSE OTHER THAN FOR WHICH IT WAS ISSUED AND Electrical Ladder Diagram AGREES TO RETURN IT UPON REQUEST.

  • Page 84: Detergent (Chemical Mixing) System Plumbing Schematic

    Detergent (Chemical Mixing) System Plumbing Item Description Solution Tank Shutoff Valve Inline Solution Filter Solution Pump Check Valve Detergent Pump Reducer Tee Reducer Coupler Solution Solenoid Valve Detergent Tank Reducer Coupler Solution Nozzles 84 - Form No. 56043161 - Clean Track ®...

  • Page 85: Detergent (Chemical Mixing) System Preparation And Use

    Detergent (Chemical Mixing) System Preparation and Use Common Instructions: Non-Refillable Cartridge Specific Instructions: The system should be purged of previous detergent when switching to a Fill the detergent cartridge with a maximum of 1.25 gallons (4.73 Liters) different detergent. of detergent. Service Note: Remove the detergent cartridge from the detergent box prior to filling to avoid spilling detergent on the machine.

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