Nilfisk-Advance Warrior ST Service Manual
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Nilfisk-Advance Warrior ST Service Manual

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Warrior ST, Warrior AXP, Warrior EcoFlex

Service Manual

Nilfisk-Advance Warrior™ ST, Warrior™ AXP, Warrior™ EcoFlex™ model number:
56315040 (X28D-C), 56315041(X32D-C), 56315541(X28C-C), 56315542(X32C-C),
56307250(X28D-C), 56315786 (32D-C), 56315036 (28D), 56307250(X28D-C), 56315037(32D),
56315038(28C) 56315538(28D-C), 56315539(32D-C), 56315540(28C-C) 56315039(32C-C),
56381014(X28D-C), 56381015 (X32D-C), 56381023(X32D-C), 56381024(X28C-C),
56381028(X32C-C), 56381017 WARRIOR X32D-C W/STRAINER, 56315584 WARRIOR 32D-C
WAL-MART, 56381023 (X32D-C W/STRAINER)
English
09/11 Revised 06/12 Form No.
56043156

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Summary of Contents for Nilfisk-Advance Warrior ST

  • Page 1: Service Manual

    Warrior ST, Warrior AXP, Warrior EcoFlex Service Manual Nilfisk-Advance Warrior™ ST, Warrior™ AXP, Warrior™ EcoFlex™ model number: 56315040 (X28D-C), 56315041(X32D-C), 56315541(X28C-C), 56315542(X32C-C), 56307250(X28D-C), 56315786 (32D-C), 56315036 (28D), 56307250(X28D-C), 56315037(32D), 56315038(28C) 56315538(28D-C), 56315539(32D-C), 56315540(28C-C) 56315039(32C-C), 56381014(X28D-C), 56381015 (X32D-C), 56381023(X32D-C), 56381024(X28C-C), 56381028(X32C-C), 56381017 WARRIOR X32D-C W/STRAINER, 56315584 WARRIOR 32D-C...

  • Page 2: Table Of Contents

    Service Manual – Warrior ST, AXP, EcoFlex Page ii Contents General Information Service Manual Purpose and Application Revision History Other Reference Manuals Conventions Transporting the Machine Cautions and Warnings Symbols General Safety Instructions Nameplate Know Your Machine — Major components:...
  • Page 3 Service Manual – Warrior ST, AXP, EcoFlex Page iii Battery Voltage (AXP/Ecoflex Models) Speed Controller Status Forward/Reverse Status Reverse Status Test Mode Output Controls Description of Output Controls Sample Voltage Measurements Electrical System Functional Description Description Of The Low-Voltage Cutout Feature...
  • Page 4 Service Manual – Warrior ST, AXP, EcoFlex Page iv Scrub Brush Motor Special Tools Scrub System, Disc Functional Description Brush Motors Brush Lift Actuator Circuit Overview Maintenance and Adjustment Lift Actuator Limit Adjustment Removal and Installation Scrub Deck Lift Actuator...
  • Page 5 Service Manual – Warrior ST, AXP, EcoFlex Page v Speed Control Potentiometer Function Speed Controller J10 Pinout Functions Troubleshooting Drive Controller (Curtis 1228) Throttle Potentiometer Testing and Adjustment Removal and Installation Throttle Potentiometer Drive Controller Follow-up Testing Wheels Drive Motor and Transaxle...

  • Page 6: General Information

    These decals are shown to the right. The basic machine is the Warrior ST. The two advanced feature machines are the AXP and EcoFlex models Revision History •...

  • Page 7: Conventions

    Service Manual – Warrior ST, AXP, EcoFlex General Information Conventions Forward, backward, front, rear, left or right are intended with reference to the operator’s position, that is to say in operating position with the hands on the handlebar Transporting the Machine Caution! Before transporting the machine on an open truck or trailer, make sure that •...

  • Page 8: General Safety Instructions

    Service Manual – Warrior ST, AXP, EcoFlex General Information General Safety Instructions Warning! ◦ This machine should be used only by properly trained and authorized persons ◦ Never work under a machine without safety blocks or stands to support the machine.

  • Page 9: Nameplate

    The Warrior machine is a battery-powered, walk-behind, self-propelled floor scrubber with either a disc or cylindrical scrub system. The Warrior ST is a configuration with a gravity-fed, pre-mix solution system. The Warrior AXP and EcoFlex machines utilize on-board chemical (detergent) injection of the solution. The Extended Scrub option (available only on AXP models) reduces the frequency of refilling the solution tank, by reusing a portion of the recovered solution from the floor surface.

  • Page 10: Specifications

    (6) 6 volt batteries (wet acid and gel cell available) Optional Onboard 36 volt, 25 amp Wet/Gel Compatible Battery Charger Precision-flow electric pump - EcoFlex system (Pulse-control gravity feed -Warrior ST) Solution Control Solution Tank 30 gal. (114 L) Recovery Tank 30 gal.
  • Page 11 Service Manual – Warrior ST, AXP, EcoFlex General Information Specifications (continued) Warrior 28D Warrior 28C Warrior 32D Warrior 32C Scrub Head Type Disc Disc Cylindrical Cylindrical 28 in (71cm) 32 in (81cm) 28 in (71cm) 32 in (81cm) Scrub Path Max Productivity 36,960 ft²/hr...

  • Page 12: Maintenance Schedule

    Service Manual – Warrior ST, AXP, EcoFlex General Information Maintenance Schedule Maintenance intervals given are for average operating conditions Machines used in severe operational environments may require service more often. Interval Maintenance Item Daily Weekly Monthly Yearly • Charge Batteries •...
  • Page 13 Warrior ST, Warrior AXP, Warrior EcoFlex Cylindrical and Disc PM Checklist Defect Codes needs adjustment Customer binding dirty or contaminated Address damaged, bent or torn leaks City missing W worn out Model Serial Hours Does OPERATIONAL INSPECTION ITEMS Defect Codes...

  • Page 14: Chassis System

    The front nose is attached to the solution tank with 4 lift-off studs for access to the scrub deck components. The front nose on a basic machine (Warrior ST) is a one-piece component. For machines with detergent systems (Warrior AXP and EcoFlex), the front nose contains a...

  • Page 15: Control System

    Service Manual – Warrior ST, AXP, EcoFlex Control System Control System Functional Description Within the Warrior system there are two primary controllers: the Warrior Controller (A1) and the Curtis Drive controller (A2). The Warrior controller controls the primary machine functions, and the Curtis controller controls the drive functions.

  • Page 16: Control Panel Indicators

    Note: automatic shutoff of the vacuum motor when the recovery tank is full is disabled when the wand is enabled. Extended Scrub (Recycle) Switch (G): Extended Scrub is available only on Warrior ST and AXP models. Pressing this switch will turn on or off the extended scrub option. When extended scrub is active, a portion of the solution to the scrub deck will come from the recovery tank.
  • Page 17 Service Manual – Warrior ST, AXP, EcoFlex Control System Scrub ON Indicators (L & M): • For Regular scrub mode, the (L) LED will be active. • For Heavy scrub mode, the (M) LED will be active. • For Extreme scrub mode, both (L&M) LED’s will be active.

  • Page 18: Scrub Mode Indicators

    The charge state of the battery is shown in the main display area of the control panel. For Warrior ST models, this is indicated by three colored LED’s (P). For Warrior AXP and EcoFlex models, this is shown with a bar graph (Q) in the main display.

  • Page 19: Main Control Board Programming

    Service Manual – Warrior ST, AXP, EcoFlex Control System transistors, with some moderately high power devices controlled with micro-relays, and very high power devices (vacuum and brush motors) controlled with external motor contactors. Another function of the main controller is to detect any system failures and display an error code on the display panel or store it in the main control board’s memory.

  • Page 20: Displaying The Control Board Revision Level

    Service Manual – Warrior ST, AXP, EcoFlex Control System Displaying the Control Board Revision Level During machine service, it may be helpful to know the control board revision level to determine machine configuration. To view the control board revision level: AXP &...

  • Page 21: Turning Fault Detection On Or Off

    Service Manual – Warrior ST, AXP, EcoFlex Control System Turning Fault Detection On or Off: If a fault occurs in a particular system, that system (and possibly others) will be shut down. This can make troubleshooting the system difficult. This option will allow service personnel to disable some of the fault detection checks to facilitate troubleshooting.

  • Page 22: Scrub Deck Type

    Service Manual – Warrior ST, AXP, EcoFlex Control System Scrub Deck Type Note: This procedure may be completed concurrently with the Chemical Option and Extended Scrub Option procedures Warrior models can be equipped with numerous scrub deck options. This function configures the Warrior controller for each of the scrub deck types.

  • Page 23: Extended Scrub Option

    Note: This procedure may be completed concurrently with the Scrub Deck Type and Chemical Option procedures Warrior ST and AXP models may be equipped with the extended scrub system. To enable or disable this option, do the following: Turn the key switch to the off position.

  • Page 24: Scrub Deck Pressure, Solution Flow Rate, And Chemical Flow Rate Adjustments

    Service Manual – Warrior ST, AXP, EcoFlex Control System Scrub Deck Pressure, Solution Flow Rate, and Chemical Flow Rate Adjustments Each of the scrub settings (Regular, Heavy, and Extreme) affects the scrub deck pressure, solution flow rate, and chemical flow rate (if equipped). These settings are adjustable. The default values are shown in the tables below.

  • Page 25: Regular Scrub Setting Adjustment

    Press the Scrub Off switch (E) to save the new setting and move to the chemical rate setting (or the end of the program mode for Warrior ST). 10 Chemical Rate Setting: (Not available on Warrior ST) The display will now show chemical bottle with current chemical setting Solution indicator will turn green and chemical indicator will turn green 11 Press the Chemical switch (H) to scroll through the 9 chemical settings.

  • Page 26: Heavy Scrub Setting Adjustment

    Press the Scrub Off switch (E) to save the new setting and move to the chemical rate setting (or the end of the program mode for Warrior ST). 10 Chemical Rate Setting: (Not available on Warrior ST) The display will now show the chemical bottle with current chemical setting Solution indicator will turn green and chemical indicator will turn green 11 Press the Chemical switch (H) to scroll through the 9 chemical settings.

  • Page 27: Extreme Scrub Setting Adjustment

    Press the Scrub Off switch (E) to save the new setting and move to the chemical rate setting (or the end of the program mode for Warrior ST). 10 Chemical Rate Setting: (Not available on Warrior ST) The display will now show the chemical bottle with current chemical setting Solution indicator will turn green and chemical indicator will turn green 11 Press the Chemical switch (H) to scroll through the 9 chemical settings.

  • Page 28: Recovery Tank-Full Switch Orientation

    Service Manual – Warrior ST, AXP, EcoFlex Control System Recovery Tank-Full Switch Orientation Use this procedure if installing a new control board on an older Normally Closed Warrior machine that uses the recovery tank full switch in the (former orientation) normally closed orientation.

  • Page 29: Monitor Mode (Warrior Axp/Ecoflex)

    Service Manual – Warrior ST, AXP, EcoFlex Control System Monitor Mode (Warrior AXP/EcoFlex) The Warrior is equipped with a monitor mode where the current deck setting, low-voltage cutout setting, and error checking setting can be quickly checked for the machine’s specific set up.

  • Page 30: Troubleshooting Guide

    Service Manual – Warrior ST, AXP, EcoFlex Control System Troubleshooting Guide Any error codes detected by the main control board will be displayed on the display panel as they occur. If more than one error exists the display will sequence through the error codes at one-second intervals. On AXP/EcoFlex models the error (T) will display as a mechanical wrench symbol followed by a two-digit code.
  • Page 31 Service Manual – Warrior ST, AXP, EcoFlex Control System The sum of the currents through these coils is too high Solenoid Bank Coil Circuit • Inspect the “B-3” ground bus (J2-9 wire) at the controller Overload • Brush Motor Contactor (K1) for negative battery voltage.

  • Page 32: Service Test Mode

    Service Manual – Warrior ST, AXP, EcoFlex Control System Service Test Mode To assist in the troubleshooting and servicing of the electrical system and related components, a special test mode allows independent control of the various outputs and monitoring of the various inputs To enter the service test mode perform the following step: Turn the key switch to the off position.

  • Page 33: Test Mode Output Controls

    Service Manual – Warrior ST, AXP, EcoFlex Control System Test Mode Output Controls The control panel switches are used to control various output functions of the Warrior controller while in Test Mode. Below is a list of each switch and the function it controls. Following the list is a detailed...
  • Page 34 Service Manual – Warrior ST, AXP, EcoFlex Control System • Check for short circuit* in brush motor or wiring. • Inspect gearbox for failure (disc). Repair or replace. • Inspect scrub brush drive bearings for excessive wear (cyl.). Scrub On Switch (I) This switch is used to control the output to the scrub deck lift actuator.
  • Page 35 Service Manual – Warrior ST, AXP, EcoFlex Control System • NO voltage, replace the Main control board Brief Off Green Flash – Vacuum motor output is on and vacuum motor current is not being sensed (abnormal condition). • Check Vacuum Motor wiring plug, disconnection.

  • Page 36: Sample Voltage Measurements

    Service Manual – Warrior ST, AXP, EcoFlex Control System Sample Voltage Measurements Examining signals sent and received at the control board can be very effective in determining if external components are functioning as expected or if the control board is processing them as expected. The tables below show sample voltage measurements taken from a Warrior machine.
  • Page 37 Service Manual – Warrior ST, AXP, EcoFlex Control System Warrior Controller Sample Voltage Measurements at the J2 Connector Pin # Name Voltage Ref. Comments J2-1 Lift Actuator U 0.20 A DPDT relay inside the control board reverses polarity for Up and Down. J2-1 and J2-8 should have mirrored voltages.

  • Page 38: Electrical System

    Description Of The Battery Condition Indicators The Battery Condition Indicator will give an indication of the state of charge of the batteries based on the voltage of the batteries. The Warrior ST display has three colored LED’s (3) showing 5-levels of voltage. The Warrior AXP/ EcoFlex display has 5 vertical bars (1) showing 6-levels of voltage.

  • Page 39: Maintenance And Adjustments

    Service Manual – Warrior ST, AXP, EcoFlex Electrical System Maintenance and Adjustments Charging Batteries Charge the batteries each time the machine is used or when the battery indicator (1 or 3) is reading less than full Note: Refer to the algorithm chart in Advance Technical Service Bulletin TSBUS2008-984 for the correct charging algorithm for your battery type and model.

  • Page 40: Troubleshooting

    Service Manual – Warrior ST, AXP, EcoFlex 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.

  • Page 41: Specifications

    Service Manual – Warrior ST, AXP, EcoFlex Electrical System Specifications Wet Cell Battery specifications: • Use a combination of multiple 6-volt units to construct a 36 Volt DC battery pack system. • Advance recommended battery pack capacity is a 305 AH @ 20 Hour Rate deep cycle battery system.

  • Page 42: Wiring Diagram

    Service Manual – Warrior ST, AXP, EcoFlex Electrical System Wiring Diagram The wiring diagram below is a general representation of the wiring within all Warrior machine models up to the publication date of this manual This diagram and actual machine wiring are subject to change Some...

  • Page 43: Options And Accessories

    Service Manual – Warrior ST, AXP, EcoFlex Options and Accessories Options and Accessories The Warrior machine is available in three basic configurations, ST, AXP, and EcoFlex. It also has a few options that may be added to these configurations, such as different sized scrub decks and squeegee assemblies.

  • Page 44: Recovery System

    Service Manual – Warrior ST, AXP, EcoFlex Recovery System Recovery System Functional Description The recovery system extracts Vacuum Recovery wastewater from the floor and Inlet Screen Tank Cover deposits it into the on-board 30 gallon recovery tank. The Recovery floor squeegee is wider than the...

  • Page 45: Float Switches

    Service Manual – Warrior ST, AXP, EcoFlex Recovery System Float Switches Depending on the machine configuration, there will be 1 or 3 float switches in the recovery tank. The recovery tank full switch is present on all machines and senses when water reaches the upper limit in the tank.

  • Page 46: Vacuum Motor Control Circuit Overview

    Service Manual – Warrior ST, AXP, EcoFlex Recovery System Vacuum Motor Control Circuit Overview Contactor Coil Circuit: Positive voltage is always present at the contactor coil (K2) through the F2 circuit breaker. The contactor coil is controlled by the switching of the negative terminal via the J1-12 terminal of the Warrior control board (A1).

  • Page 47: Troubleshooting

    Service Manual – Warrior ST, AXP, EcoFlex 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 and clean the vacuum motor float switch. Note that on current models, if the switch is closed (tipped up) the vacuum motor will not operate.

  • Page 48: Removal And Installation

    Service Manual – Warrior ST, AXP, EcoFlex Recovery System Removal and Installation Vacuum Motor Turn off the key and disconnect the batteries. Drain the recovery tank and move it to the open position Disconnect the vacuum motor cable connector. Remove the screw and washer from the discharge...

  • Page 49: Float Switches

    Service Manual – Warrior ST, AXP, EcoFlex Recovery System Float Switches Use this procedure to replace the float switches in the Recovery Tank. All machines will have a Recovery Float Arm Orientation Tank Full switch. Machines with the Extended Scrub...

  • Page 50: Scrub System, Cylindrical

    Service Manual – Warrior ST, AXP, EcoFlex Scrub System, Cylindrical Scrub System, Cylindrical Functional Description The scrub system consists of a motorized scrub deck that is raised and lowered with a lift actuator The two Brush Motor counter rotating brushes are driven by independent Contactor motors with integral speed reduction gear boxes.

  • Page 51: Brush Lift Actuator

    Service Manual – Warrior ST, AXP, EcoFlex Scrub System, Cylindrical Brush Lift Actuator The scrub deck is raised and lowered with a motorized actuator The top of the actuator connects to the Solution Tank, and the bottom of the actuator connects to the Limit Switch scrub deck.

  • Page 52: Maintenance And Adjustment

    Service Manual – Warrior ST, AXP, EcoFlex Scrub System, Cylindrical Maintenance and Adjustment Lift Actuator Limit Adjustment To protect the lift actuator from traveling too far, it contains two internal limit switches for minimum and maximum travel. The minimum travel is adjusted by...
  • Page 53 Service Manual – Warrior ST, AXP, EcoFlex Scrub System, Cylindrical Hold the spring housing from rotating, and press the For/Rev button of the Adapter (1) to lower the actuator to its lowest position until the motor stops (maximum limit switch engaged).

  • Page 54: Removal And Installation

    Service Manual – Warrior ST, AXP, EcoFlex Scrub System, Cylindrical Removal and Installation Scrub Deck Remove the front nose from the machine Put the scrub deck in a neutral position by either lowering it to the floor or blocking it up to remove the weight Disconnect the main battery connector in the battery compartment.

  • Page 55: Lift Actuator

    Service Manual – Warrior ST, AXP, EcoFlex Scrub System, Cylindrical Lift Actuator Remove the front nose from the machine Disk Deck Shown Put the scrub deck in a neutral position by either Cylinder Deck Similar lowering it to the floor or blocking it up to remove...

  • Page 56: Brush Motor Contactor

    Service Manual – Warrior ST, AXP, EcoFlex Scrub System, Cylindrical Brush Motor Contactor Warning: Disconnect the battery connector before servicing machine. Turn off the key and disconnect the main battery connector Free the drive paddle control wire from the wire...

  • Page 57: Scrub Brush Motor

    Service Manual – Warrior ST, AXP, EcoFlex Scrub System, Cylindrical Scrub Brush Motor Turn off the key and disconnect the main battery connector. Disconnect the motor cable connector and free up any cables from cable ties Remove the screw and washer that secure the drive belt cover (25) to the scrub deck, and remove the cover.

  • Page 58: Scrub System, Disc

    Service Manual – Warrior ST, AXP, EcoFlex Scrub System, Disc Scrub System, Disc Functional Description Brush Motor Brush Motor Contactor Gear Box Lift Scrub Deck Accuator Housing Brush Plate Brush Scrub Deck, Disc Type The scrub system consists of a motorized scrub deck that is raised and lowered with a lift actuator. The two counter rotating brushes are driven by independent motors with integral speed reduction gear boxes.

  • Page 59: Brush Lift Actuator

    Service Manual – Warrior ST, AXP, EcoFlex Scrub System, Disc Brush Lift Actuator The scrub deck is raised and lowered with a motorized leadscrew actuator The top of the actuator connects to the Solution Tank, and the bottom of the actuator Limit Switch connects to the scrub deck.

  • Page 60: Maintenance And Adjustment

    Service Manual – Warrior ST, AXP, EcoFlex Scrub System, Disc Maintenance and Adjustment Lift Actuator Limit Adjustment To protect the lift actuator from traveling too far, it contains two internal limit switches for minimum and maximum travel. The minimum travel is adjusted by...
  • Page 61 Service Manual – Warrior ST, AXP, EcoFlex Scrub System, Disc Hold the spring housing from rotating, and press the For/Rev button of the Adapter (1) to lower the actuator to its lowest position until the motor stops (maximum limit switch engaged).

  • Page 62: Removal And Installation

    Service Manual – Warrior ST, AXP, EcoFlex Scrub System, Disc Removal and Installation Scrub Deck Remove the front nose from the machine Put the scrub deck in a neutral position by either lowering it to the floor or blocking it up to remove the weight Disconnect the main battery connector in the battery compartment.

  • Page 63: Lift Actuator

    Service Manual – Warrior ST, AXP, EcoFlex Scrub System, Disc Lift Actuator Remove the front nose from the machine Put the scrub deck in a neutral position by either lowering it to the floor or blocking it up to remove...

  • Page 64: Brush Motor Contactor

    Service Manual – Warrior ST, AXP, EcoFlex Scrub System, Disc Brush Motor Contactor Warning: Disconnect the battery connector before servicing machine. Turn off the key and disconnect the main battery connector Free the drive paddle control wire from the wire...

  • Page 65: Scrub Brush Motor

    Service Manual – Warrior ST, AXP, EcoFlex Scrub System, Disc Scrub Brush Motor Turn off the key and disconnect the main battery connector Disconnect the motor cable connector and free up any cables from cable ties You may find it easier to access the mounting...

  • Page 66: Solution System

    Non-detergent Models Machines that do not have detergent mixing (Warrior ST Model) use a gravity-fed solution system to the scrub deck. A solution solenoid, located downstream from the solution filter, activates to allow solution to flow to the scrub deck.

  • Page 67: Extended Scrub Models

    Service Manual – Warrior ST, AXP, EcoFlex Solution System, Downstream from the solution pump is the chemical (detergent) injection system. The detergent is stored in the removable detergent tank, which has a suction hose from the chemical pump. The chemical pump draws the liquid from the detergent tank and injects it into the solution line between the solution pump and the solution solenoid.

  • Page 68: Circuit Overview

    Service Manual – Warrior ST, AXP, EcoFlex Solution System, Circuit Overview Solenoid Valve Circuit The positive terminal (brown wire) of the solution solenoid receives unswitched +36V battery power through the 5 amp circuit breaker (F2). The negative terminal (red/green wire) of the solution solenoid is connected to the Warrior controller at J1-11 The solenoid is active when the controller forces the J1-11 terminal to GND.

  • Page 69: Solution System Schematic

    Service Manual – Warrior ST, AXP, EcoFlex Solution System, Solution System Schematic...

  • Page 70: Troubleshooting

    Service Manual – Warrior ST, AXP, EcoFlex Solution System, Troubleshooting Exit Service mode. If solution doesn’t Replace the Curtis While in the Service flow in normal operation, the Curtis drive controller Flow Test Mode, activate drive controller is likely not communicat- the Solution button.

  • Page 71: Removal And Installation

    Service Manual – Warrior ST, AXP, EcoFlex Solution System, Removal and Installation Solution Pump Turn off the key and disconnect the battery. Free up the wire bundle from around the solution pump and disconnect the pump’s power connector Loosen the two hose clamps (4) that secure the...

  • Page 72: Squeegee System

    Service Manual – Warrior ST, AXP, EcoFlex Squeegee System Squeegee System Squeegee Functional Description Suction Hose The squeegee tool collects wastewater from the floor for the recovery system to lift the Squeegee water into the recovery tank. The Lift Lever...

  • Page 73: Maintenance And Adjustment

    Service Manual – Warrior ST, AXP, EcoFlex Squeegee System Maintenance and Adjustment Squeegee Blade Cleaning and Inspection Periodically clean and inspect the squeegee tool (4) and blades (5&6). Remove the squeegee tool from the pivot/lift assembly (2) by removing the suction hose (1) and loosening the two thumb nuts (3) Clean the squeegee blades (5&6) and suction area...

  • Page 74: Squeegee Lift Adjustment

    Service Manual – Warrior ST, AXP, EcoFlex Squeegee System Squeegee Lift Adjustment The squeegee tool’s storage and operation positions are adjustable. In the operation (down) position the lifting cable should be slacked, yet still have sufficient travel to lift the squeegee too off the floor when not in...

  • Page 75: Front Squeegee Blade Reversal Or Replacement

    Service Manual – Warrior ST, AXP, EcoFlex Squeegee System Front Squeegee Blade Reversal or Replacement Raise the squeegee off the floor and remove the squeegee tool (4) from the pivot/lift assembly (2) by removing the suction hose (1) and loosening...

  • Page 76: Wheel System, Non-Traction

    Service Manual – Warrior ST, AXP, EcoFlex Wheel System, Non-Traction Wheel System, Non-Traction Functional Description The Warrior machine is propelled by the drive wheels The rear caster wheels add stability and ease of turning Caster Wheels Removal and Installation Warning: Never work under machine without safety stands or blocking to support the machine.

  • Page 77: Wheel System, Traction

    Service Manual – Warrior ST, AXP, EcoFlex Wheel System, Traction Wheel System, Traction Functional Description The Warrior machine is driven by an Control Paddle electrically powered transaxle. A 1/2 hp, permanent magnet, 36V motor drives the transaxle. A Curtis PMC solid state speed...

  • Page 78: Drive Motor System Function

    Service Manual – Warrior ST, AXP, EcoFlex Wheel System, Traction Drive Motor System Function 1-Cycle (15kHz) The drive motor is controlled from a Curtis PMC 1228 controller, which is a pulse-width-modulation speed controller designed specifically for 25% PWM Duty Cycle permanent magnet DC motors.

  • Page 79: Speed Control Potentiometer Function

    Service Manual – Warrior ST, AXP, EcoFlex Wheel System, Traction Speed Control Potentiometer Function The two potentiometers on the operator control paddle are set up in a voltage-division scheme across the Pot-Low (0V) and Pot-High (5V) outputs of the speed controller. As the potentiometer wiper moves through its resistance range, the wiper voltage varies from 0V to 5V.

  • Page 80: Troubleshooting

    Service Manual – Warrior ST, AXP, EcoFlex Wheel System, Traction Troubleshooting Problem Cause Correction • Reset the 30A circuit breaker Wheel drive motor will not Wheel drive motor circuit run in either forward or breaker (F3) tripped reverse. • Reset the 5A circuit breaker...
  • Page 81 Service Manual – Warrior ST, AXP, EcoFlex Wheel System, Traction Status Led Fault Codes Code Explanation Possible Cause • Temperature >92°C or < -25°C Over/under-temperature • Excessive load on vehicle cutback • Operation in extreme environments • Electromagnetic brake not releasing Throttle fault •...

  • Page 82: Throttle Potentiometer Testing And Adjustment

    Service Manual – Warrior ST, AXP, EcoFlex Wheel System, Traction Throttle Potentiometer Testing and Adjustment The drive motor speed controller has several safety protocols to prevent unwanted drive operation in the event of faulty input signals from the throttle potentiometer (16) If the total resistance of the throttle...

  • Page 83: Removal And Installation

    Service Manual – Warrior ST, AXP, EcoFlex Wheel System, Traction Removal and Installation Throttle Potentiometer Turn the key switch to the off position. Remove the four screws (12) that secure the paddle front cover (14) to the paddle back housing (13), and remove the front cover...
  • Page 84 Service Manual – Warrior ST, AXP, EcoFlex Wheel System, Traction Before installing the potentiometer, it is necessary to locate the shaft midpoint position, where the resistance between the wiper and outer terminals is equal. This coarse adjustment makes it easier to set the...

  • Page 85: Drive Controller

    Service Manual – Warrior ST, AXP, EcoFlex Wheel System, Traction Drive Controller Warning: Disconnect the battery connector before servicing machine. Note: Drive controllers are factory pre-programmed for the Warrior machine. Use only factory authorized replacement controllers. Turn off the key and disconnect the main battery...

  • Page 86: Follow-Up Testing

    Service Manual – Warrior ST, AXP, EcoFlex Wheel System, Traction Follow-up Testing After replacing the drive controller, perform this follow-up testing procedure to ensure safe operation of the controller Before reconnecting the battery, either block the wheels off the ground or move the machine to an open area without obstructions Reconnect the battery connector and turn on the key switch.

  • Page 87: Wheels

    Service Manual – Warrior ST, AXP, EcoFlex Wheel System, Traction Wheels Warning: Disconnect the battery connector before servicing machine. Warning: Never work under machine without safety stands or blocking to support the machine. Turn off the key and disconnect the batteries.

  • Page 88: Drive Motor And Transaxle

    Service Manual – Warrior ST, AXP, EcoFlex Wheel System, Traction Drive Motor and Transaxle Warning: Disconnect the battery connector before servicing machine. Warning: Never work under machine without safety stands or blocking to support the machine. Turn off the key and disconnect the batteries.
  • Page 89 Service Manual – Warrior ST, AXP, EcoFlex Wheel System, Traction Disconnect the motor connector (10) from the main wiring harness Remove the ground wire (11) from the transaxle housing Note: During reassembly, make sure all wires are secured and not dragging below the machine.

  • Page 90: Special Tools

    Service Manual – Warrior ST, AXP, EcoFlex Wheel System, Traction Special Tools Curtis 1311 Programmer The Curtis 1311 Programmer (or the 1307 predecessor) may be used to display drive controller error codes and program the drive controller. With a programmer, diagnostics and troubleshooting is more direct than with the Warrior display alone.

This manual is also suitable for:

Warrior axpWarrior ecoflex

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