Nilfisk-Advance 56414010 Service Manual Download

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Contents

Service Manual – SC6500

™

Cylindrical Scrub System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . 103

Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

General Scrub System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 106

Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Weekly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Monthly Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Scrub Brush Belt Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Lift Actuator Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Using the Actuator Power Cord Adapter

. . . . . . . . . . . . . . . . . . . . . 108

Lift Actuator Drive Nut Adjustment . . . . . . . . . . . . . . . . . . . . . . . 109

Side Skirt Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . 113

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Scrub Brushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Scrub Brush Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Scrub Deck Lift Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Scrub Brush Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Shop Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Brush Contactor (K2, K3 or K4)

. . . . . . . . . . . . . . . . . . . . . . . . . 121

Scrub Brush Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Brush Actuator Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Scrub System, Disc 123

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Disc Scrub System Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . 123

Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Lift Actuator Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Using the Actuator Power Cord Adapter

. . . . . . . . . . . . . . . . . . . . . 126

Lift Actuator Drive Nut Adjustment . . . . . . . . . . . . . . . . . . . . . . . 127

Side Skirt Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . 131

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Scrub Brush Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Scrub Deck Lift Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Scrub Brush Motor and Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

To Remove and Install a Gearbox Assembly . . . . . . . . . . . . . . . . . . . 136

To Disassemble and Reassemble a Gearbox Assembly . . . . . . . . . . . . . 136

Specifications

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Shop Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Scrub Brush Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Solution System 139

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Solution Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Shutoff Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Drain Hose and Hose Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Solution Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Solution Control Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Summary of Contents for 56414010

Page 1: ...3 SC6500 40D ECOFLEX 56414014 SC6500 45C 56414015 SC6500 45C ECOFLEX 56414016 SC6500 45D 56414017 SC6500 45D ECOFLEX 56414018 SC6500 48C 56414019 SC6500 48C ECOFLEX 56414020 SC6500 48D 56414021 SC6500 48D ECOFLEX Nilfisk Model Numbers 56414022 SC6500 1100D 56414023 SC6500 1100C 56414024 SC6500 1300D 56414025 SC6500 1300C 56414026 SC6500 1100D ECOFLEX ...

Page 2: ...w 19 Major Machine Components 19 Control Panel 21 Switch and Button Functions 21 Control Panel Indicators 24 Control Panel Display 26 Caution Displays 26 Circuit Breakers 27 General Maintenance 27 Maintenance After Use 27 Maintenance Schedule 28 Machine Lubrication 29 Lubrication Points 29 PM Check List SC6500 30 Chassis System 32 Major Chassis Components 32 Control System 33 Functional Descriptio...

Page 3: ...pecifications 54 I O Table with Shop Measurements 55 A2 Control Board Assembly 55 Electrical System 59 Functional Description 59 Overview 59 Low voltage Cut out Feature 59 Battery Condition Indicator 59 Component Locations 61 Battery Location 63 Connector Pin Outs 64 J1 Connects to A2 Control Board 64 J2 Connects to A2 Control Board 65 J3 Connects to A3 Display Panel 65 X6 Connects to A1 Speed Con...

Page 4: ...ring Harness Diagram 56414096_REV_C 85 Options and Accessories 86 Recovery System 90 Functional Description 90 Overview 90 Recovery Tank 90 Vacuum Motor 90 Squeegee and Squeegee Hose 90 Float Cage and Ball 91 Recovery System Wiring Diagram 91 Circuit Description 92 Component Locations 92 Vacuum Motor and Vacuum Hose 92 Top Cover Assembly 93 Float Cage and Ball 93 Recovery Tank Lid 94 Squeegee and ...

Page 5: ...ush Motor 121 Brush Actuator Motor 122 Special Tools 122 Scrub System Disc 123 Functional Description 123 Overview 123 Disc Scrub System Wiring Diagram 123 Circuit Description 124 Component Locations 125 Maintenance and Adjustments 126 Lift Actuator Adjustment 126 Using the Actuator Power Cord Adapter 126 Lift Actuator Drive Nut Adjustment 127 Side Skirt Replacement and Adjustment 131 Troubleshoot...

Page 6: ... decks only 148 To Purge the Detergent System 148 To Purge the Detergent System When Changing Detergents 149 To Program the Detergent Ratio 149 Troubleshooting 150 Removal and Installation 152 Solution Control Pump 152 Solution Solenoid Valve 153 Specifications 154 Solution Flow Rates 154 Component Specifications 154 Shop Measurements 154 Squeegee System 155 Functional Description 155 Overview 155...

Page 7: ...hooting 171 Removal and Installation 172 Side Broom Lift Actuator 172 Side Broom Gearmotor 173 Specifications 174 Shop Measurements 174 Side Broom Contactor K6 174 Side Broom Motor 174 Side Broom Actuator Motor 174 Special Tools 175 Wheel System Non traction 176 Functional Description 176 Overview 176 Component Locations 176 Maintenance and Adjustments 177 Brake Cable Adjustment 177 Brake Caliper ...

Page 8: ...ve Pedal Installation 207 Drive Pedal Neutral Adjustment and Pedal Replacement 207 Wheel Drive Controller Replacement 208 Specifications 208 General Specifications 208 Speed Mode Table 209 Specifications 210 Shop Measurements 210 Wheel Drive Controller Voltage Measurements 210 Low Current 35 Pin Connector X6 210 Motor U V and W Terminal Pair Voltages 211 Motor U V and W Terminal Pair Frequency 212...

Page 9: ...ft front and rear in this manual are as seen from the Operator s seat position Feedback All comments and suggestions for improving this manual should be emailed to servicemanuals nilfisk advance com Please include the service manual title form number revision date found on the front cover with your communication Revision History Date Details 01 2015 First Release Other Manuals and Information Sour...

Page 10: ...ded for selecting the correct technical documentation and when ordering repair parts for the machine Part No on the label is equivalent to the machine Model Number Note that the Nameplate is attached to the rear of the steering column Transporting the Machine Caution Before transporting the machine on an open truck or trailer make sure that The machine is tied down securely using approved tie down...

Page 11: ...e severe personal injury Caution Is used to call attention to a situation that could cause minor personal injury or damage to the machine or other property Read all instructions before using General Safety Instructions Specific Cautions and Warnings are included to warn you of potential danger of machine damage or bodily harm Warning This machine is to be used only by correctly trained and authori...

Page 12: ... the brush drive system When operating this machine ensure that third parties particularly children are not endangered Before performing any service function carefully read all instructions pertaining to that function Do not leave the machine unattended without first turning the key switch off O removing the key and applying the parking brake Turn the key switch off O and remove the key before cha...

Page 13: ...erator control panel circuit breaker panel or any electrical areas of the machine Emergency stop Switch Battery Disconnect The Emergency stop Battery Disconnect is the red lever located to the right of the Operator s seat In the event of an emergency press the Emergency stop Battery Disconnect in toward the rear of the machine to disconnect the battery from the machine This will stop all machine f...

Page 14: ...g 2792 1266 2842 1289 2892 1312 Maximum Wheel Floor Loading center front psi kg cm2 116 8 15 116 8 15 116 8 15 Maximum Wheel Floor Loading right rear psi kg cm2 81 5 69 81 5 69 81 5 69 Maximum Wheel Floor Loading left rear psi kg cm2 86 6 04 86 6 04 86 6 04 Vibrations at the Hand Controls ISO 5349 1 m s2 1 12m s2 1 12m s2 1 12m s2 Vibrations at the Hand Controls ISO 5349 1 Uncertainty m s2 11 m s2...

Page 15: ...o brushes per machine inch cm 38 37 97 4 Brush Diameter Disc inch cm Quantity of 2 20 50 8 Quantity of 3 at 16 40 6 Quantity of 3 at 17 43 Scrub Brush Speed Cylindrical RPM 630 630 630 Scrub Brush Speed Disc RPM 240 225 225 Brush Motor Power hp kW 40C 2 x 1 5 1 13 40D 1 x 3 0 2 24 45C 2 x 1 5 1 13 45D 3 x 1 5 1 13 48C 2 x 1 5 1 13 48D 3 x 1 5 1 13 Hopper Capacity Cylindrical ft3 L 0 40 11 0 44 12 ...

Page 16: ...front psi kg cm2 116 8 15 116 8 15 Maximum Wheel Floor Loading right rear psi kg cm2 81 5 69 81 5 69 Maximum Wheel Floor Loading left rear psi kg cm2 86 6 04 86 6 04 Vibrations at the Hand Controls ISO 5349 1 m s2 1 12m s2 1 12m s2 Vibrations at the Hand Controls ISO 5349 1 Uncertainty m s2 11 m s2 11 m s2 Vibrations at the Seat EN 1032 m s2 0 35m s2 0 35m s2 Vibrations at the Seat EN 1032 Uncerta...

Page 17: ... two brushes per machine inch cm 38 37 97 4 Brush Diameter Disc inch cm Quantity of 2 20 50 8 Quantity of 3 at 17 43 Scrub Brush Speed Cylindrical RPM 630 630 Disc RPM 240 225 Hopper Capacity Cylindrical ft3 L 0 40 11 0 50 14 Cleaning Path Width scrubbing path inch cm 40 101 48 122 Sweeping Path with side brooms Cylindrical inch cm 57 145 Gross Weight Standard machine without options full solution...

Page 18: ...General Information 18 Service Manual SC6500 Dimensions 58 5 148 6 cm Width with Squeegee 73 5 187 cm Machine Width at Rollers TOP VIEW SIDE VIEW ...

Page 19: ...Wheel Solution Tank Fill Cover Control Panel Circuit Breakers Steering Wheel Tilt Adjust Knob Drive Steer Wheel Brake Pedal Parking Brake Battery Compartment underneath recovery tank Machine Battery Connector Emergency stop Switch Battery Disconnect Scrub Deck Side Access Panel Drive Pedal Direction Speed Operator s Seat Adjustment Lever Recovery Tank Lid ...

Page 20: ...eegee Vacuum Hose Squeegee Height Adjust Knob Squeegee Tilt Adjust Knob Squeegee Assembly Squeegee Height Adjust Knob Solution Tank Drain Hose Solution Shutoff Valve Solution Filter Hopper cylindrical models only Recovery Tank Drain Hose Recovery Tank Cover Assembly ...

Page 21: ... the wheel drive speed control Scrub On Pressure Increase Switch functions as follows If the scrub system is off pressing this switch once will put the machine into the Auto Scrub mode The following will occur The scrub system will be enabled with the scrub pressure set to the 1 normal setting Note Press the switch twice for 2 heavy scrub setting and three times for the 3 extreme scrub setting Pre...

Page 22: ... Solution Switch functions as follows If the scrub system is off pressing and holding this switch will switch on the solution flow to pre wet the floor The solution flow will stop when the switch is released Note this must be done prior to pressing the Scrub On Switch and putting the machine into the Auto Scrub mode If the machine is in the Auto Scrub mode pressing this switch will disable the sol...

Page 23: ... of transport speed Traction Control Switch regulates the drive wheel motor torque to minimize drive wheel slippage in limited traction conditions Side Broom On Down Switch lowers and raises the side brooms only functional on cylindrical models equipped with side brooms Note that when the scrub system is switched on the side brooms are lowered to the same position they were in when the scrub syste...

Page 24: ...Panel Display displays the various icons that indicate scrub pressure solution flow rate detergent ratio battery charge state and a recovery tank full condition The display also shows any error conditions detected by the main control board Control Panel Indicators In general the following guidelines apply to the control panel indicators When the key switch is first turned on all of the blue or gre...

Page 25: ...gent System Indicator The indicator will light when the detergent system is enabled and or is switched on The indicator will be off when the detergent system is off Note The control board automatically recognizes that the machine has an operational detergent system through its wiring harness connection Vacuum Wand Indicator The indicator will light when the vacuum system is enabled and or is switc...

Page 26: ...icator solution flow rate and scrub pressure If the detergent system is enabled the display will also show the detergent system indicator and the current detergent solution ratio If an A2 Control Board error occurs the display will show a wrench icon to indicate an error and display a two digit error code number If more than one error exists the display will sequence through the error codes at one...

Page 27: ...ion Tank Drain Hose from its storage clamp b Direct the Solution Tank Drain Hose to a designated disposal site and remove the Solution Tank Drain Hose Plug c Rinse the tank with clean water 4 To empty and clean the recovery tank a Pull the Recovery Tank Drain Hose from its storage area b Direct the Recovery Tank Drain Hose to a designated disposal site and remove the Recovery Tank Drain Hose Plug ...

Page 28: ...es Pads X Check Clean the Squeegee X Check Clean Vacuum Shutoff Float X Check Clean the Vacuum Motor Foam Filter s X Clean Hopper on Cylindrical System X Check the Water Level in each Battery Cell X Inspect Scrub Housing Skirts X Inspect and Clean Solution Filter X Check Foot Parking Brake For Wear and Adjustment X Clean Solution Dispensing Trough on Cylindrical System X Purge Detergent System X S...

Page 29: ...o the components shown Apply grease to Squeegee Caster Wheel Axle and Pivot Steering Wheel Shaft Universal joint Steering Chain Squeegee mount angle adjustment knob threads Apply light machine oil to Squeegee tool end wheels Recovery Tank release latch Brake Pedal parking brake linkage Machine Lubrication Lubrication Points Grease Grease Grease or Anti seize Oil Oil Oil Grease Grease Grease or Ant...

Page 30: ...king A B W 5 Drive System Performance reference Service Manual for Curtis drive programmer speed changes noisy sluggish 6 Scrub System Raise Lower and auto scrubbing functions A B 7 Scrub Brush Pressure Settings see Service Manual programming 3 different modes A B 8 Squeegee System Raise Lower and auto lift in reverse function A B 9 Vacuum Performance sealed water lift 70 and 1 inch open hole adap...

Page 31: ... M 30 Recovery Tank Cover Gasket Air leaks C D L 31 Recovery Tank Drain Hose and Cap Flush C L 32 Squeegee Pick Up Tool and Hose Back flush C L 33 Squeegee Blades clean and rotate A C D W 34 Squeegee Mount Wheels lubricate 4 Grease Fittings A C W 35 Squeegee Lift Actuator Motor and Lifting Bar A B D 36 Battery Pack Condition clean and water Load Test C W 37 Front Drive Wheel Motor Carbon Brushes C...

Page 32: ...Chassis System 32 Service Manual SC6500 Chassis System Major Chassis Components 45 in 48in 1300mm models only ...

Page 33: ... on the lift actuator motor to move the scrub deck downward until the brush motor current draw is within the correct range for the scrub pressure selected If the brush motor current rises above the desired range the A2 Control Board Assembly switches on the lift actuator motor to lift the scrub deck upward until the brush motor current draw is again within the correct range for the scrub pressure ...

Page 34: ...all Mode Whenever the A2 Control Board Assembly detects an electrical system error or fault one or more error codes are displayed and stored by the A2 Control Board Assembly You can recall error codes if any from previous machine operation for troubleshooting purposes To recall stored error codes 1 Turn the key switch off 2 Press and hold the solution switch 3 While holding the solution switch tur...

Page 35: ...h icon The factory default scrub pressures have now been restored 5 Turn the key switch off To Enable Disable the Fault Detection Note that the factory default for fault detection is OFF You can enable or disable open circuit fault detection with this setting If the setting is set to off the controller will still detect and set faults for over current conditions To turn the fault checking on or of...

Page 36: ...y switch off 2 Press and hold the detergent switch 3 While holding the detergent switch turn the key switch on 4 Continue to hold the detergent switch until the detergent system indicator switches on 5 Release the detergent switch The display will show the following current machine programmed settings Scrub deck type and size Detergent mode on off Fault detection on off Vacuum motor selection VACU...

Page 37: ...d indicator turns on and the normal scrub on indicator blinks 5 Release both switches The display will now show a scrub icon either disc or cylindrical with the current scrub pressure setting 6 Press the scrub on switch to increment the scrub pressure setting as shown by the number of bars in the display 7 Press the scrub off switch to save the new scrub pressure setting and move to the solution f...

Page 38: ... solution flow rate as shown by the number of bars in the display 9 Press the scrub off switch to save the new solution flow rate setting and move to the detergent concentration setting The display will now show the detergent icon with a 0 or next to it The solution system indicator will stop blinking and the detergent indicator will blink 10 Press the detergent switch to scroll through and select...

Page 39: ...by 10 percent Selecting will decrease the detergent concentration in the detergent ratios by 10 percent 11 Press the scrub off switch to save the detergent concentration setting and display the key switch icon 12 Turn the key switch off The new settings will be saved until changed again Scrub Speed Switch Lockout Note that the factory default setting for the scrub speed switch is FAST SLOW ENABLE ...

Page 40: ...n turn the key switch on 4 Continue to hold the button for two seconds until the EcoFlex and scrub off indicators turn on 5 Release the EcoFlex button The display will now show the ECOFLEX MODE OFF ECOFLEX MODE MODE 1 and ECOFLEX MODE MODE 2 menu 6 Press the EcoFlex button to scroll through the menu and select the desired ECOFLEX MODE On the SC6500 there is no difference in machine operation wheth...

Page 41: ...nd the scrub off indicator will turn on The display will now show a text message REC TANK FULL DETECT ENABLE or DISABLE 6 Press the vacuum wand switch to toggle between ENABLE or DISABLE ENABLE means that the automatic shutoff feature is turned on DISABLE means that the automatic shutoff feature is turned off 7 Press the scrub off switch to save the setting and display the key switch icon 8 Turn t...

Page 42: ...ght intensity levels 7 Press the scrub off switch to save the setting and display the key switch icon 8 Turn the key switch off The new setting will be saved until changed again Detergent and Solution Pump Purge The EcoFlex detergent system has two purge flush programs to ensure that the detergent delivery hoses and related components are kept open and clean A general operational description in ho...

Page 43: ...oom actuator run time raises the side broom height To adjust the side broom height 1 Turn the key switch off 2 Press and hold the side broom on down and scrub off switches 3 While holding the switches turn the key switch on 4 Continue to hold the switches until the side broom on down indicator scrub off indicator and both scrub on indicators turn on 5 Release the switches The indicators will stay ...

Page 44: ...de 1 Turn the key switch off 2 Press and hold the scrub speed and traction control switches 3 While holding the scrub speed and traction control switches turn the key switch on 4 Continue to hold the scrub speed and traction control switches until the traction control indicator lights 5 Release the scrub speed and traction control switches The scrub speed indicator will turn off and the display wi...

Page 45: ...the deck reaches the up position the normal scrub indicator will blink Pressing the switch a fourth time will switch off the normal scrub indicator Vacuum Wand Switch This switch controls the squeegee lift actuator and vacuum motor s as follows Pressing the switch the first time will switch on vacuum motor s and switch on the actuator to lower the squeegee The vacuum wand indicator will light as t...

Page 46: ... Off Solenoid and solution pump outputs are off Steady Blue Solenoid and solution pump outputs are on Detergent Switch This switch controls the detergent pumps Pressing and releasing this switch will alternately turn the detergent pumps on and off The detergent system indicator provides the following status information Off Detergent pump output is off Steady Blue Detergent pump output is on Troubl...

Page 47: ...rush motor contactor coil overload Contactor K4 is for the left motor on the three motor decks The nominal coil resistance is 94 ohms for all three motor contactors 1 Check for a K4 coil wiring problem or a short circuit wire colors VIO and GRA RED 2 Check the coil resistance If the resistance is below 75 ohms replace the coil 06 Center brush motor contactor coil overload Contactor K3 is for the c...

Page 48: ...istance Replace the solution solenoid if the coil resistance is lower than 58 ohms 13 Solution control pump overload The normal current load is 0 8 1 8 amps A current load of 3 2 amps or over will generate code 13 pump motor overload 1 Check for short circuits in the wiring and in the M12 pump motor 2 Disconnect the solution pump motor and run the machine to see if the wiring is shorted 3 Check th...

Page 49: ...sh motor contactor coil short to ground 1 Disconnect the K4 coil wiring wire colors VIO and GRA RED and check to see if the code disappears If the code disappears replace the brush contactor If the code does reappear test the wiring for a short back to the battery ground Repair or replace the defective wire 2 If the above test doesn t remove the code substitute a new A2 control board assembly 24 C...

Page 50: ...k for 36 Volts at the vacuum motor If 0 Volts replace the vacuum motor contactor K1 30 Vacuum motor contactor coil open 1 Check for an open circuit in the K1 coil and wiring wire colors VIO and BLU 2 Test for 36V at the K1 coil If 0 Volts check the A2 control board assembly 31 K1 Vacuum motor contactor coil short to ground 1 Disconnect the K1 coil wiring wire colors VIO and BLU and check to see if...

Page 51: ...and BRN BLK and check to see if the code disappears If the code disappears replace the K6 contactor If the code does reappear test the wiring for a short back to the battery ground Repair or replace the defective wire 2 If the above test doesn t remove the code substitute a new A2 control board assembly 38 Side broom actuator motor open 1 Use an ohmmeter to check for an open circuit in the M4 side...

Page 52: ...re to ground for short circuit wire colors ORN BRN battery and BLU WHT battery Repair or replace the defective wiring 2 Disconnect the alarm and test to see if the circuit wiring is still causing an error code shorted If not replace the back up alarm Short Circuit definition A short circuit is a parallel path of very low resistance often caused accidentally With low resistance there is an excessiv...

Page 53: ...er assembly located to the left of the operator position Make sure to unplug the fan assembly before removing the electrical panel cover assembly from the machine 2 Disconnect the electrical connectors from the A2 Control Board Assembly 3 Remove the five Screws holding the A2 Control Board Assembly to the Electrical Mount and remove the A2 Control Board Assembly from the machine 4 Install the A2 C...

Page 54: ...amps Heavy Scrub 2 bars 2 50 amps 45 amps 60 amps 45 amps Extreme Scrub 3 bars 3 65 amps 55 amps 80 amps 55 amps Solution Flow Rates Standard flow rates Override flow rates 1 bar 2 bars 3 bars 4 bars 5 bars 40 Disc 0 84 GPM 1 00 GPM 1 50 GPM 2 00 GPM 2 50 GPM 40 Cylindrical 0 70 GPM 0 84 GPM 1 00 GPM 1 50 GPM 2 50 GPM 45 48 Disc 1 00 GPM 1 50 GPM 2 00 GPM 2 25 GPM 2 50 GPM 45 48 Cylindrical 0 84 G...

Page 55: ...ttery Voltage 36V B ground 31V 38V 36 7V Downstream of circuit breaker F1 Key switch S1 Diode D1 Seat Switch S2 and Battery Interlock Switch S3 Output J1 6 TAN BRN Detergent Pump1 Pulsed Voltage 0 or 36V B ground see comment below 11 17V Line should alternate between 0V and 36V when detergent pump is activated Measured in service test mode Output J1 7 BLK GRA Detergent Pump1 Pulsed Voltage 0 or 36...

Page 56: ... Not measured Should be same as J1 16 or J1 19 Output J1 18 YEL GRN L1 Solenoid Valve Pulsed Voltage 0 or 36V B ground see comment 37 4V off 0 1V on Line should alternate between 0V and 36V when solenoid is activated Output J1 19 YEL BLU K2 Right Brush Contactor Voltage 0V B ground 0 1V 37 4V off 0 1v on Output J1 20 BLU RED Horn Voltage 0V B ground 0 1V 37 4V off 0 4V on Output J1 21 BLU ORN Solu...

Page 57: ...om Actuator Voltage 36V B ground see comment 36 4V up 0 4V down 2 9V rest 36V while lowering 36V while raising Output J2 8 GRA VIO Side Broom Actuator Voltage 36V B ground see comment 36 8V down 4 1 4V up 2 8V rest 36V while lowering 36V while raising Output J2 9 BLU BRN Squeegee Actuator Voltage 36V B ground see comment 36 8V up 0 5v down 2 9V rest 36V while lowering 36V while raising Input J2 10...

Page 58: ...e 0V B ground 0 1V 37 4V off 0 13V on Output J2 23 BLU WHT Backup Alarm Voltage 0V B ground 12 6V off 0 1V on It is difficult to validate the signal using a voltmeter An LED test light such as a logic probe is a better indicator The Solution Pump line provides a switched ground return for the pump When the solution pump is on a 5KHz signal with a varying duty cycle and a peak voltage of 36 volts w...

Page 59: ...huts down The drive motor will still operate in the low voltage cut out mode to allow the machine to be driven to a charging location The low voltage cut out level is adjustable The standard lead acid battery wet cell setting is 1 72 volts per cell The alternate maintenance free battery gel cell setting is 1 81 volts per cell The standard lead acid battery setting is factory selected and should be...

Page 60: ...tual battery voltage Battery Indicator Standard Alternate 5 vertical indicator bars 36 1 36 1 4 vertical indicator bars 35 5 36 1 35 5 36 1 3 vertical indicator bars 34 4 35 5 34 4 35 5 2 vertical indicator bars 33 9 34 4 33 9 34 4 1 vertical indicator bars 32 2 33 9 33 3 33 9 0 vertical indicator bars 30 9 32 2 32 8 33 3 Low voltage Cut out 30 9 32 8 ...

Page 61: ...light optional Not shown H4 Horn Inboard of solution filter K1 Contactor Vacuum K2 Contactor Right Brush all models K3 Contactor Center Brush 45 48 disk and all cyl K4 Contactor Left Brush 45 48 disk only K5 Contactor Auxiliary K6 Contactor Side Brooms K7 Contactor Main Speed Controller S1 Switch Key S2 Switch Seat S3 Switch Battery Interlock with battery roll out option F4 250 Amp Fuse Circuit Br...

Page 62: ...Electrical System 62 Service Manual SC6500 H4 Horn Solution Filter S2 Seat Switch S3 Battery Interlock Switch K1 Vacuum K2 Right Brush K3 Center Brush K4 Left Brush K5 Auxiliary K6 Side Brooms K7 Main ...

Page 63: ...ttery Location The Batteries are located in the battery compartment behind the operator seat and underneath the recovery tank The Battery Disconnect is mounted on the right side of the operator seat Battery Disconnect Battery 6 Battery Disconnect ...

Page 64: ...18 1 2 BRN BLU 18 1 3 GRN BLU 18 1 4 ORN RED 18 1 5 GRN 18 2 6 TAN BRN 18 1 7 BLK GRA 18 1 8 ORN 18 3 9 ORN BRA 18 1 10 BLK 16 3 11 RED WHT 18 1 12 YEL RED 18 1 13 GRA 18 1 14 BLK 16 4 15 VIO 16 1 16 WHT VIO 18 1 17 GRA RED 18 1 18 YEL GRN 18 1 19 YEL BLU 18 1 20 BLU RED 18 1 21 BLU ORN 18 1 22 WHT BRN 18 1 23 VIO 16 2 ...

Page 65: ... YEL GRA 18 1 6 RED BLK 18 1 7 GRN ORN 18 1 8 GRA VIO 18 1 9 BLU BRN 18 1 10 BLK 16 1 11 12 13 14 BLK 16 2 15 BRN BLK 18 1 16 GRN WHT 18 1 17 VIO YEL 18 1 18 ORN BRN 18 1 19 BLU BLK 18 1 20 BLK WHT 18 1 21 BLK ORN 18 1 22 BLU 18 1 23 BLU WHT 18 1 J3 Connects to A3 Display Panel Pin No Wire ID 1 WHT BRN 18 1 2 GRA 18 1 3 GRN BLU 18 1 4 BRN BLU 18 1 ...

Page 66: ...Controller Pin No Wire ID 1 ORN 2 3 ORN RED 4 YEL RED 5 RED WHT 6 BLK YEL 7 BLK PINK 8 TAN RED 9 GRN 10 BLU BLK 11 BLK WHT 12 13 14 15 VIO BLK 16 BRN RED 17 18 WHT BLK 19 20 21 22 23 24 25 VIO WHT 26 PINK RED 27 28 WHT ORN 29 BLU GRN 30 31 PINK WHT 32 PINK BLU 33 34 35 ...

Page 67: ...LU W005 3 BLK PNK W004 4 TAN RED W003 5 PNK WHT W002 6 BLK PNK W001 X8 Connector for Curtis Programmer Pin No Wire ID 1 BLU GRA 18 1 2 BLK PINK 18 6 3 WHT ORN 18 1 4 VIO WHT 18 1 X10 Connects to S3 Battery Interlock Switch X9 if equipped If not connects to X51 Jumper Pin No Wire ID A GRY ORN 18 1 B GRN 18 1 ...

Page 68: ...2 Connects to H2 Flashing Lamp X11 Pin No Wire ID A BLK 18 7 B ORN 18 6 X13 connects to M12 Solution Control Pump X14 Pin No Wire ID A VIO 18 13 B BLU ORN 18 1 X16 Connects to L1 Solution Solenoid Valve X15 Pin No Wire ID A YEL GRN 18 1 B VIO 18 9 ...

Page 69: ...nnects to M2 Brush Actuator X17 Pin No Wire ID A RED BLK 18 1 B YEL GRA 18 1 X20 Connects to M3 Squeegee Actuator X19 Pin No Wire ID A WHT GRN 18 1 B BLU BRN 18 1 X22 Connects to M4 Side Broom Actuator X21 Pin No Wire ID A GRAB VIO 18 1 B GRN ORN 18 1 ...

Page 70: ...500 X29 Connects to M7 Left Side Broom Motor X27 Pin No Wire ID A BLK 18 3 B WHT RED 18 1 X30 Connects to M8 Right Side Broom Motor X28 Pin No Wire ID A BLK 18 5 B WHT RED 18 2 X32 Pin No Wire ID A VIO BLK 18 1 B BRN RED 18 1 C WHT BLK 18 1 ...

Page 71: ...ub Deck Sensing Resistor X40 Pin No Wire ID A GRN WHT 18 1 B ORN BLK 18 1 X43 Connects to S5 Solution Tank Float Switch X42 Pin No Wire ID A VIO YEL 18 1 B BLK 18 2 X49 Connects to X48 Connector of Vacuum Motor Wiring Harness Pin No Wire ID A BLU GRN 10 1 B BLK 10 8 ...

Page 72: ... an optional interlock switch Pin No Wire ID A BLK 18 8 B BLK 18 8 X55 Connects to M15 Accessory Pump Optional X54 Pin No Wire ID A VIO 18 15 B BLK 18 11 X59 Connects to Telematics Connector Jumper X59A Pin No Wire ID A ORN YEL 18 1 B ORN 18 1 C YEL BRN 18 3 D BLU 18 2 E YEL BLU 18 2 F RED WHT 18 3 G H BLK 18 12 ...

Page 73: ...BLK 18 13 C D E F G H X60 Deutsch DTM04 6P Connects to X61 Pin No Wire ID 1 PNK RED W006 2 PNK BLU W005 3 BLK PNK W004 4 TAN RED W003 5 PNK WHT W002 6 BLK PNK W001 X61 Deutsch DT M06 6s Connects to X60 Pin No Wire ID 1 PNK RED W006 2 PNK BLU W005 3 BLK PNK W004 4 TAN RED W003 5 PNK WHT W002 6 BLK PNK W001 ...

Page 74: ...achine is stored the batteries should be charged once a month to prevent the batteries from sulfating Almost all battery caps are vented so there s no need to loosen or remove them for charging Keep the batteries clean check and clean monthly Use a damp cloth to wipe dirt from the top of the batteries Battery terminals must be clean and tight If the tops of the batteries are wet after charging the...

Page 75: ...tubes Warning Do not fill the batteries before charging Charge the batteries in a well ventilated area Do not smoke while servicing the batteries When Servicing 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 ALWAYS disconnect the negative ground cable ...

Page 76: ... A dead cell is one that reads 50 points or more lower than the other cells 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 General Troubleshooting Problem Cause Correction No Power to the Machine The emergency stop switch battery disconnect by the Operator seat is not connected Connect the emergency stop ...

Page 77: ... be installed only by an Advance representative or dealer a qualified electrician or the battery manufacturer 1 Remove the batteries from their shipping crate and carefully inspect them for cracks or other damage If damage is evident contact the carrier that delivered them or the battery manufacturer to file a damage claim 2 Turn the key switch off and remove the key 3 Remove the recovery tank fro...

Page 78: ...erminal will not turn Do not overtighten the terminals or they will be very difficult to remove for future service 7 Coat the terminals with spray on battery terminal coating available at most auto parts stores 8 Put one of the black rubber boots over each of the terminals and connect the Battery Disconnect ...

Page 79: ...ttery pack voltage and the input AC line voltage supply being used When selecting a battery charger always follow the recommendation of the battery supplier to match the correct charger DC output amperage to the amp hour rating batteries being installed This will prevent the battery pack from being overcharged or undercharged The recommended 395 AH battery should be matched to a 36 volt 36 amp out...

Page 80: ...bottom margins of the sheet to define vertical columns and 1 5 printed on the right and left margins of the sheet to define rows The sheet number and grid coordinates make up an address and are used for locating an area on the sheet where an item may be found The address begins with the sheet number followed by the letter and number that define the coordinates on the sheet In the example below the...

Page 81: ...r the symbol the circuit will be identified by a wire color a description of the circuit or a unique letter The circuit identification must be used to match the mating termination point There is also an address of where to find the mating termination point See examples below Continued Symbols Circuit Description Identification Wire Color Identification Address of mating termination point To find a...

Page 82: ...3 EXTENDS MEANS WITH THE POSITIVE OF THE BATTERY CONNECTED TO THE RED ACTUATOR TERMINAL THE ACTUATOR WILL EXTEND 2 FOR NORMAL OPERATION WITHOUT TELEMATICS A JUMPER NEEDS TO BE IN PLACE ON CONNECTOR X59 PINS 1 AND 2 1 REFERENCE WIRING DIAGRAM 56414096 NOTES TO 3C2 TO 3C4 TO 3C4 TO 3C4 TO 1B2 To 1C2 TO 3C3 3 3 3 5 OPTIONAL NONE EXTENDS J2 8 TO 2B1 TO 2F1 C JDK JDK JDK UPDATE TELEMATICS CONNECTOR 5V ...

Page 83: ... A 1 B C D E F G A B C D E F G 2 3 4 5 1 2 3 4 5 56414095 SEE SHEET 1 2 0F 3 X6 6 X6 1 X6 11 MODE 2 X6 4 DIRECTION X6 3 FAULT B W V B U X6 9 A1 WHEEL DRIVE CONTROLLER 5V X6 26 PHASE B X6 32 PHASE A X6 31 TEMP SENSOR GND X6 7 TEMP SENSOR X6 8 TX X6 28 RX X6 29 PROGRAMMER CONNECTOR 12V X6 25 FOR REV X6 10 MODE 1 THROTTLE POT WIPER X6 16 5V THROTTLE POT HIGH X6 15 B THROTTLE POT LOW X6 18 X6 5 MOTION...

Page 84: ...INNESOTA 55447 3408 DRAWN PROJ ENG C NILFISK ADVANCE INC ORCAD A 1 B C D E F G A B C D E F G 2 3 4 5 1 2 3 4 5 ON 40 DISK ON 40 DISK USED AS LEFT OR RIGHT ON CYL USED AS LEFT OR RIGHT ON CYL 56414095 3 0F 3 PMO WCR 56414095 SC6500 10 28 13 56414094 10 28 13 3 of 3 DIAGRAM LADDER TO 1B3 TO 1B3 TO 1B3 TO 1B3 TO 1B3 NONE TO 2B5 TO 2F5 WHT RED WHT RED VIO BLK BLK BLK BLK BLK BLK BLU GRN RED RED RED RE...

Page 85: ...LK GRA 18 1 VIO 16 2 GRA 18 1 BLU RED 18 1 BRN 18 1 RED BLK 18 1 BRN BLU 18 1 GRN BLU 18 1 VIO YEL 18 1 GRN ORN 18 1 ORN 18 3 BLK ORN 18 1 VIO 16 1 ORN BRN 18 1 BRN BLK 18 1 YEL RED 18 1 ORN YEL 18 1 GRA VIO 18 1 ORN BLU 18 1 TAN BRN 18 1 YEL GRN 18 1 WHT GRN 18 1 BLU BRN 18 1 YEL GRA 18 1 GRA RED 18 1 YEL BLU 18 1 BLU 18 1 RED WHT 18 2 ORN RED 18 1 BLU BLK 18 1 ORN BLK 18 1 BLU WHT 18 1 BLK 16 1 ...

Page 86: ...Options and Accessories 86 Service Manual SC6500 Options and Accessories Description Heavy duty front bumper Tube Bumper Kit Spray Wand ...

Page 87: ...Options and Accessories 87 Service Manual SC6500 Description Warning Beacon Back Up Alarm Overhead Guard ...

Page 88: ...Options and Accessories 88 Service Manual SC6500 Description Seat Belt Standard Seat Deluxe Grammer Seat 2nd vacuum motor kit ...

Page 89: ...Options and Accessories 89 Service Manual SC6500 Description Headlight Operator Foot Guard Solution Auto Fill Recovery Drain Hose Extension ...

Page 90: ...used to pick up solution already on the floor or when using a wand on the Squeegee Hose A current sensor monitors the Vacuum Motor current and will display a fault if the Vacuum Motor current draw is too high Squeegee and Squeegee Hose The wastewater and air enter the vacuum system at the Squeegee tool through small openings notches located in the front Squeegee blade The small openings are the en...

Page 91: ... board which automatically shuts off the vacuum and scrub systems The LCD will then display the recovery tank full indicator icon to alert the operator that the recovery tank needs to be drained Recovery System Wiring Diagram A2 Control Board Assembly A3 Switch Display Panel Assembly Fuse 250 A 36V Battery A1 Speed Controller Motion 8 B B F4 K7 F1 S1 S2 S3 D1 Key Switch Seat Switch Battery Interlo...

Page 92: ...rs the voltage input from the Vacuum Motor Shunt wire connected to the ground side of Vacuum Motors M5 and M6 If the voltage is out of the acceptable range 07 12 volts for a single vacuum motor or 15 24 volts for dual vacuum motors the A2 Control Board Assembly will sense that the float ball is sealed against the float cage and that the recovery tank is full The A2 Control Board Assembly will then...

Page 93: ...d Float Ball attach to the bottom of the Recovery Tank Top The Vacuum Fan Top Gasket seals the Top Cover Assembly to the recovery tank Float Cage and Ball The Float Ball is retained inside the two piece interlocking Float Cage The assembled Float Cage and Float Ball attach to the bottom of the Recovery Tank Top Vacuum Filter Lid Filter Filter Screen Wire Rope Recovery Tank Top Vacuum Fan Top Gaske...

Page 94: ... Squeegee and Drain Hoses The Squeegee Hose and Drain Hoses are mounted on the rear of the Recovery Tank The Squeegee Hose connects the squeegee to the inlet port on the Recovery Tank The Drain Hose allows you to drain the Recovery Tank by removing the Drain Hose Cap Recovery Tank Lid Squeegee Hose Drain Hose Cap Drain Hose Recovery Tank ...

Page 95: ...ing 5 Replace the Vacuum Filter Lid To Inspect and Clean the Vacuum Motor Float Cage 1 Lift the Recovery Tank Lid to access the Float Cage and captive float ball The Float Cage is attached to the underside of the Top Cover Assembly 2 Carefully remove the Float Cage from the Top Cover Assembly Note that the Float Cage is a two piece design and can be snapped apart to separate for cleaning 3 Clean a...

Page 96: ...tive motor bearings repair or replace 4 Check for a short circuit in the vacuum motor or wiring repair or replace Vacuum motor contactor coil overload error code 10 displayed 1 Check for a K1 coil wiring problem or short circuit wire colors VIO and BLU 2 Check the coil resistance If the coil resistance is below 80 ohms replace the coil Vacuum motor open error code 29 displayed 1 Check for disconne...

Page 97: ... Cracked squeegee vacuum hose Cracked recovery tank Vacuum motor is weak Troubleshooting Steps Begin with a good visual inspection of the system Check the condition of the squeegees and the recovery hose Take the recovery hose off and rinse it out Check the recover tank cover gasket condition Repair any problems found If no visual problems are found test the system using a vacuum gauge PN 56205281...

Page 98: ... one inch open hole adapter between the hose end and the vacuum gauge 4 Turn the vacuum motor on and measure the vacuum If it is within 10 of the specs the vacuum system is working properly If the reading is too low check for a restriction in the system ...

Page 99: ...y Tank 1 Drain the recovery tank 2 Disconnect the squeegee hose from the squeegee tool and from the top of the recovery tank twist the hose to remove Note Removing the squeegee tool at the mount will allow more room to maneuver when removing the recovery tank 3 Disconnect the Vacuum Motor Wiring Connector located underneath the left rear bottom of the recovery tank 4 Release the Tank Latch and til...

Page 100: ...ine Caution Be careful not to crush or damage the drain hose when pulling the tank from the chassis 8 To reinstall the tank a Align each side of the tank bracket with the chassis pins one at a time b Grip the opening of the tank cover at the rear and quickly lift up to set engage the tank in its upright position c Reconnect the Tank Tether to the back of the operator seat d Swing the tank up to th...

Page 101: ...ing cavity 6 Inspect the following vacuum system gaskets and replace as necessary Vacuum Filter Lid Gasket Vacuum Fan Top Gasket RS Strip Gasket Vacuum Fan Gaskets 7 Clean the vacuum motor Filter Filter Screen and Vacuum exhaust Hose 8 Inspect the carbon motor brushes If the carbon brushes are less than 3 8 10 mm in length replace the brushes 9 Reinstall the Vacuum Motor by following the above ste...

Page 102: ...ealed 74 in H2 O Open Hole Adapter 1 27 in H2 O Shop Measurements Shop measurements are values that were measured on a real machine While they are not specifications they can help you recognize normal vs abnormal K1 Vacuum Contactor Resistance at room temperature 93 ohms Vacuum Motor Current draw for one motor with open squeegee hose 18 7 Amps Special Tools Vacuum water lift gauge Nilfisk Advance ...

Page 103: ...he desired scrub pressure Cylindrical Scrub System Wiring Diagram A2 Control Board Assembly A3 Switch Display Panel Assembly Fuse 250 A 36V Battery A1 Speed Controller Motion 8 B B F4 K7 F1 S1 S2 S3 D1 Key Switch Seat Switch Battery Interlock Switch for roll out Battery Diode F2 Circuit Breaker 15 Amp Circuit Breaker 3 Amp K5 4 3 16 15 Direction Battery Ground CAN H CAN L S5 Solution Empty Switch ...

Page 104: ...CAN BUS that the operator has pressed the scrub on switch the A2 Control Board Assembly sends the appropriate voltage to the Brush Actuator M2 to lower the scrub deck to the operating position The Scrub Deck Sensing Resistor R2 senses the deck size so the operator does not need to program the deck size into the hidden menu As the brush motor current passes through the BRN current sense wire which ...

Page 105: ...ect scrub pressure The Hopper Assembly holds the dust and debris swept up by the scrub brushes and can be removed for dumping and cleaning The Side Skirts direct the waste water to the squeegee and help keep the water confined within the cleaning path The Side Skirt height is adjustable and the Side Skirts can be removed for cleaning or replacement Scrub Motor 2 Poly V Sheave Drive Belt 2 under Be...

Page 106: ...n delivery trough on top of the scrub deck Clean any built up dirt from the inside of the scrub brush housing Remove any string wrapped around the scrub brushes drive hubs and idler hubs Remove both the scrub brushes and rotate end for end Refer to the Removal and Installation Scrub Brushes section Monthly Maintenance Inspect the scrub brush bristles for wear the brushes should be replaced when th...

Page 107: ...le pulling outward on the belt to roll the belt off of the pulleys 4 Place the new belt on the large pulley and then use a plastic wire tie to hold the belt on the pulley 5 Loop the belt over the small pulley and hold it on 6 Use a 1 2 drive extension and ratchet in the large pulley slot to rotate the pulley to roll the belt onto the pulley ...

Page 108: ...s set by adjusting an internal cam under the rubber cover of the actuator motor Using the Actuator Power Cord Adapter The adjacent drawing shows the special actuator power cord adapter p n 56407502 that is needed to connect the machine s battery pack and actuator motor for setting the actuator drive nut limit settings To connect the actuator power cord adapter 1 Open the machine battery compartmen...

Page 109: ...ousing Refer to the photo below If the housing and springs are already assembled disassemble them 3 Lubricate the lead screw threads using bearing grease 4 Install the spring cap into the upper spring The upper spring is shorter and lighter than the lower spring Then install the upper spring and cap onto the lead screw with the cap toward the motor housing 5 Rotate the drive nut onto the lead scre...

Page 110: ... p n 56407502 run the motor toward the extended position until the motor stops This establishes the location where the extended travel limit switch opens a Measure the distance between the nut on the lead screw and the motor housing It should be 5 1 2 inches 14 cm b If the distance is not correct remove the rubber cam adjuster cover with a screwdriver in the motor housing to gain access to the cam...

Page 111: ... the housing over the lead screw springs and drive nut Align the slotted holes in the housing with the pin holes in the drive nut c Install the two nut retainers inserting their pins into the drive nut pin holes Secure the two nut retainers together using two screws Pin Pin Hole d Slightly compress the upper spring and install the 4 spring housing retaining screws You can compress the spring by ho...

Page 112: ...ssembly dimensions refer to the Removal and Installation Scrub Deck Lift Actuator section to reassemble it in the machine Refer to the adjacent drawing to correctly mount the top of actuator motor to the chassis by model size Service Note Note the correct orientation of the Spring Housing Assembly when installing the complete motor assembly and also run the Spring Housing Assembly to the Retracted...

Page 113: ... main Skirt Blade has four working edges as shown Turn the Skirt Blade so a clean undamaged edge faces toward the center of the machine Replace the Skirt Blades as a set if all four edges are nicked torn or worn beyond their ability to be adjusted 4 Reinstall the Side Skirt Assemblies onto the machine and check the height of the Skirt Blades for correct contact on the floor when the brush deck is ...

Page 114: ...IO and WHT VIO 2 Check the coil resistance If the resistance is below 75 ohms replace the coil Note that the nominal coil resistance is 94 ohms for both motor contactors Right brush motor contactor coil overload error code 07 displayed 1 Check for a K2 coil wiring problem or a short circuit wire colors VIO YEL BLU 2 Check the coil resistance If the resistance is below 75 ohms replace the coil Scru...

Page 115: ...titute a new A2 control board assembly The scrub deck actuator doesn t raise or lower the scrub deck Scrub deck actuator overload error code 08 displayed Normal current load is 1 3 amps Max current load is 6 amps Max current with no load is 1 4 amps 1 Check for binding or a frozen brush lift linkage and excessive weight on the brush deck 2 Check for a short circuit in the actuator motor and wiring...

Page 116: ... Knobs then slide the Side Skirt Assembly forward slightly then off of the scrub deck 3 Loosen the Thumb Nut on top of the Broom Idler Assembly until the Broom Idler Assembly drops down far enough to disengage it from the Notches then remove the Broom Idler Assembly 4 Remove the Brush from the housing 5 To reinstall a Brush slide it into the housing lift it slightly then push and turn the Brush un...

Page 117: ...ve bottom lift actuator Cotter Hair Pin then push the Retainer Pin from its housing and mount bracket holes 7 Disconnect the actuator wire harness connector Note that this will prevent the actuator from being switched on and rising when it is disconnected from its deck mount Service Note Connect the Advance power cord adapter p n 56407502 to the lift motor harness then position relieve the pressur...

Page 118: ...7502 to the actuator motor and use the adapter to shorten the Scrub Deck Actuator length Hold the Spring Housing Assembly when you run the Scrub Deck Actuator motor to maintain the correct retracted and extended position settings See the Lift Actuator Adjustment section in this manual for additional details An alternate method to get the needed actuator clearance to slide the deck out from under t...

Page 119: ...from underneath the middle of the machine 3 Slide the actuator Mount Pin from the housing and frame mounting bracket holes allowing the motor to drop down completing its removal 4 Refer to the Drive Nut Adjustment section for instructions on how to install a new drive nut and set the extended and retracted positions 5 Install the scrub deck actuator by following the above steps in reverse order Se...

Page 120: ...ul and watch your fingers as the motor will drop 7 Turn the Scrub Motor clockwise to access the motor terminal studs Note the wire connections for correct reassembly then remove both motor wires 8 Lower the deck assembly to the deck actuator s maximum down position travel to get the clearance needed to remove the motor from the machine You can do this either of two ways Reconnect the battery then ...

Page 121: ... 0 0 5 Amps Full Load Thrust 600 lbs Speed 29 3 in min 5 0 1 Amps Stall Current 25 Amps max Start Thrust 600 lbs min Shop Measurements Shop measurements are values that were measured on a real machine While they are not specifications they can help you recognize normal vs abnormal Brush Contactor K2 K3 or K4 Resistance at room temperature 93 ohms Scrub Brush Motor 40C and 1100C deck with no load b...

Page 122: ...m Cylindrical 122 Service Manual SC6500 Brush Actuator Motor 45 inch cylindrical deck Current draw going up 3 5 4 0 Amps Current draw going down 1 2 2 2 Amps Special Tools Actuator Power Cord Adapter p n 56407502 ...

Page 123: ...iagram A2 Control Board Assembly A3 Switch Display Panel Assembly Fuse 250 A 36V Battery A1 Speed Controller Motion 8 B B F4 K7 F1 S1 S2 S3 D1 Key Switch Seat Switch Battery Interlock Switch for roll out Battery Diode F2 Circuit Breaker 15 Amp Circuit Breaker 3 Amp K5 4 3 16 15 Direction Battery Ground CAN H CAN L S5 Solution Empty Switch closes when empty B B B Bat Bat Bat Bat K2 Right Brush Cont...

Page 124: ...lay Panel Assembly via the CAN BUS that the operator has pressed the scrub on switch the A2 Control Board Assembly sends the appropriate voltage to the Brush Actuator M2 to lower the scrub deck to the operating position The Scrub Deck Sensing Resistor R2 senses the deck size so the operator does not need to program the deck size into the hidden menu As the brush motor current passes through the BR...

Page 125: ...ally adjusts the deck height during scrubbing to maintain the correct scrub pressure The Side Skirts direct the waste water to the squeegee and help keep the water confined within the cleaning path The Side Skirt height is adjustable and the Side Skirts can be removed for cleaning or replacement K2 Right Brush K3 Center Brush K4 Left Brush Location K1 Vacuum K2 Right Brush K3 Center Brush K4 Left ...

Page 126: ...ting an internal cam under the rubber cover of the actuator motor Using the Actuator Power Cord Adapter The adjacent drawing shows the special actuator power cord adapter p n 56407502 that is needed to connect the machine s battery pack and actuator motor for setting the actuator drive nut limit settings To connect the actuator power cord adapter 1 Open the machine battery compartment and disconne...

Page 127: ...ng Refer to the photo below If the housing and springs are already assembled disassemble them 3 Lubricate the lead screw threads using bearing grease 4 Install the spring cap into the upper spring The upper spring is shorter and lighter than the lower spring Then install the upper spring and cap onto the lead screw with the cap toward the motor housing 5 Rotate the drive nut onto the lead screw th...

Page 128: ...n 56407502 run the motor toward the extended position until the motor stops This establishes the location where the extended travel limit switch opens a Measure the distance between the nut on the lead screw and the motor housing It should be 5 1 2 inches 14 cm b If the distance is not correct remove the rubber cam adjuster cover with a screwdriver in the motor housing to gain access to the cam ad...

Page 129: ... housing over the lead screw springs and drive nut Align the slotted holes in the housing with the pin holes in the drive nut c Install the two nut retainers inserting their pins into the drive nut pin holes Secure the two nut retainers together using two screws Pin Pin Hole d Slightly compress the upper spring and install the 4 spring housing retaining screws You can compress the spring by holdin...

Page 130: ...bly dimensions refer to the Removal and Installation Scrub Deck Lift Actuator section to reassemble it in the machine Refer to the adjacent drawing to correctly mount the top of actuator motor to the chassis by model size Service Note Note the correct orientation of the Spring Housing Assembly when installing the complete motor assembly and also run the Spring Housing Assembly to the Retracted in ...

Page 131: ... has two working edges 3 The main Skirt Blade has four working edges as shown Turn the Skirt Blade so a clean undamaged edge faces toward the center of the machine Replace the Skirt Blades as a set if all four edges are nicked torn or worn beyond their ability to be adjusted 4 Reinstall the Side Skirt Assemblies onto the machine and check the height of the Skirt Blades for correct contact on the f...

Page 132: ...sion and the condition of the idler bearing Left brush motor contactor coil overload error code 05 displayed Contactor K4 is for the left motor on the three motor decks 1 Check for a K4 coil wiring problem or a short circuit wire colors VIO and GRA RED 2 Check the coil resistance If the resistance is below 75 ohms replace the coil Note that the nominal coil resistance is 94 ohms for all three moto...

Page 133: ...l If you get 0 Volts check the A2 control board assembly Center brush motor contactor coil short to ground error code 25 displayed 1 Disconnect the K3 coil wiring wire colors VIO and WHT VIO and check to see if the code disappears If the code disappears replace the brush contactor If the code does reappear test the wiring for a short back to the battery ground Repair or replace the defective wire ...

Page 134: ... Check for an open circuit in the motor wiring or for a defective motor 3 Check for output voltage from the A2 control board assembly at the actuator wiring plug It should be 36 volts If 0 Volts check the A2 control board assembly Removal and Installation Warning Before removing or reinstalling any machine components make sure the key switch is off and the key is removed from the machine Scrub Bru...

Page 135: ...t Support Arms away from their mounting holes 11 Remove the previously installed wood blocking from underneath the drive discs Note that this must be done to get the needed clearance to remove the scrub deck 12 Carefully slide the complete deck assembly out from underneath the machine from its left side Note Observe the position of the disconnected lift actuator housing and swing it to the rear to...

Page 136: ...traight up 6 Reassemble the Gearbox Assembly to the Deck Weldment by following the above steps in reverse order Make sure to reinstall the key stock To Disassemble and Reassemble a Gearbox Assembly 1 Remove the three socket head cap screws securing the Gearbox to the Brush Motor then separate the Gearbox from the Brush Motor Make sure to save the internal Gearbox key stock for reassembly 2 Reassem...

Page 137: ... Motor Type permanent magnet 36 VDC 1 5 HP reversible Motor to drive screw ratio 19 1 1 Performance Data No Load Thrust 0 lbs Speed 36 4 in min 1 0 0 5 Amps Full Load Thrust 600 lbs Speed 29 3 in min 5 0 1 Amps Stall Current 25 Amps max Start Thrust 600 lbs min Shop Measurements Brush Contactor K2 K3 or K4 resistance at room temperature 93 ohms Scrub Brush Motor 40D and 1100D deck with no load bru...

Page 138: ...Scrub System Disc 138 Service Manual SC6500 Special Tools Actuator Power Cord Adapter p n 56407502 ...

Page 139: ...the Solution Solenoid to regulate the solution flow rate On EcoFlex models a solution pump is used to move fluid from the solution tank to the scrub deck The A2 Control Board provides pulsed width modulated PWM voltage to the Solution Control Pump to regulate the solution flow rate Note that the Solution Solenoid Valve is full open whenever the solution system is switched on On EcoFlex models when...

Page 140: ...rom reaching the solution control pump and solution solenoid valve The Solution Filter can be disassembled for cleaning Solution Control Pump The Solution Control Pump pumps the solution through the solution solenoid valve to the nozzles adjacent to the scrub brushes The Solution Control Pump gets PWM voltage from the A2 Control Board to regulate the Solution Control Pump speed and the correspondi...

Page 141: ...ttery when the load side of contactor K5 is closed The contactor K5 closes when the A2 Control Board Assembly connects the K5 coil to battery ground A2 Control Board Assembly A3 Switch Display Panel Assembly Fuse 250 A 36V Battery A1 Speed Controller Motion 8 B B F4 K7 F1 1 2 S1 S2 S3 D1 Key Switch Seat Switch Battery Interlock Switch for roll out Battery Diode F2 Circuit Breaker 15 Amp Circuit Br...

Page 142: ...M voltage but is always at full voltage when the Solution Control Pump M12 is on Detergent System The Detergent Metering Pumps M13 and M16 are powered directly by the A2 Control Board Assembly The A2 Control Board Assembly sends the Detergent Metering Pumps voltage to run the Detergent Metering Pumps when The A3 Switch Display Panel Assembly sends the A2 Control Board Assembly a signal via the CAN...

Page 143: ...h The solution level switch is a float switch in the bottom of the solution tank It reports when the tank is nearly empty The solution system indicator will flash to remind the operator of the low solution condition but the machine will continue to function S5 Solution Empty Switch Viewed from solution tank fill opening Viewed from under solution tank S5 Solution Empty Switch Shutoff Valve ...

Page 144: ...rneath the left side of the machine The Solution Filter is below the FILTER location arrow molded into the machine body panel Solution Control Pump The Solution Control Pump pumps the solution through the solution solenoid valve to the nozzles adjacent to the scrub brushes The Solution Control Pump gets PWM voltage from the A2 Control Board to regulate the Solution Control Pump speed and the subse...

Page 145: ...ol Board it remains full open when the solution pump is switched on Solution Manifold disc decks only The Solution Manifold distributes the solution from the solution pump and solenoid valve to the nozzles adjacent to the scrub brushes Accessory Pump The Accessory Pump is included in the optional Spray Wand Kit The pump mounts on the underside of the chassis Solution Solenoid Valve Solution Manifo...

Page 146: ...m 146 Service Manual SC6500 Detergent Tank and Pumps The Detergent Tank and Detergent Pumps are located behind the side access panel on the right hand side of the machine Detergent Pump Detergent Pump Detergent Tank ...

Page 147: ...lenoid valve check the valve for correct operation Weekly Maintenance To Empty and Rinse the Solution Tank 1 Remove the solution drain hose from its storage area located above the left rear tire 2 Remove the drain hose cap and direct the hose to a designated disposal site and flush the tank with clean water 3 Replace the drain hose cap and replace the drain hose in its storage area To Clean the So...

Page 148: ...holes in the Delivery Trough to ensure even solution distribution To Purge the Detergent System 1 Disconnect and remove the detergent tank 2 Install and connect a tank filled with clean water 3 Turn the key switch off 4 Press and hold both the detergent and solution switches 5 While holding the switches turn the key switch on The display will show the purge icon the detergent and solution pumps wi...

Page 149: ...e 10 available detergent ratios Select the desired detergent ratio as follows 1 Press the detergent switch to turn the detergent system off if not already off 2 Press and hold the detergent switch for two seconds to enter the ratio programming mode The detergent system indicator will blink while in the programming mode 3 Press the detergent switch to cycle through the available detergent ratios as...

Page 150: ... solenoid short to ground Main Controller Error Code 34 Disconnect the L1 solenoid coil wiring and check to see if the code disappears If the code disappears replace the solenoid If the code reappears test the wiring for a short back to the battery ground Repair or replace the defective wire Substitute a new A1 control board Solution solenoid L1 overload Main Controller Error Code 12 Check for a s...

Page 151: ...ge or damage and repair replace as necessary The detergent tank cap is not sealed on the tank Tighten the tank cap The detergent tank cap must be seated securely and tight to pull draw detergent from the tank The detergent pumps are not operating Check the wire connections at the detergent pumps for correct wiring polarity Make sure the electrical connections are tight and corrosion free With the ...

Page 152: ... from the machine Note Place a suitable container underneath the solution control pump to catch any solution that may leak from the pump or hoses 3 Disconnect the pump Electrical Connector from the machine harness 4 Remove the four 10 24 Screws Nyloc nuts and flat washers holding the Solution Control Pump to the bottom of the machine 5 Loosen the Clamps holding the Hoses to the Elbows and disconne...

Page 153: ...Disconnect the L1 solenoid valve Electrical Connector from the machine harness 4 Loosen the Hose Clamps on the Inlet and Outlet Hoses 5 Separate pry the Outlet Hose off of the barbed fitting on the Valve Body 6 Remove the two Hex Screws holding the Valve Body to the underside of the chassis then pull the Valve Body toward the front of the machine to separate it from the Outlet Hose 7 Reinstall the...

Page 154: ...0 GPM 2 00 GPM 2 50 GPM Component Specifications Component Specifications Solution Control Pump Voltage 36 VDC Current Draw 3 9 amps max Flow Rate 3 3 GPM 2 75 amps with 20 psi inlet pressure Solution Solenoid Valve Coil Voltage 36 VDC Coil Resistance 74 ohms Accessory Pump Voltage 36 VDC Current Draw 3 0 amps max Pressure Control Setting 100 5 psi Maximum Flow Rate 1 6 gal min Detergent Pump Volt...

Page 155: ...ts voltage from the A2 Control Board Assembly which switches the polarity to move the squeegee tool up or down When the A2 Control Board Assembly receives a signal from the A3 Switch Display Panel Assembly via the CAN BUS that the operator has pressed the scrub on switch the A2 Control Board Assembly sends the appropriate voltage to the Squeegee Actuator M3 to lower the squeegee to the operating p...

Page 156: ...ystem is switched off Moving the drive pedal back to the neutral forward switches off the reverse direction output from the A1 Speed Controller to the A2 Control Board Assembly The A2 Control Board Assembly then sends voltage to the Squeegee Actuator M3 at the appropriate polarity to lower the squeegee tool back onto the floor Component Locations The Squeegee Assembly is attached to the Squeegee M...

Page 157: ...icked torn or worn to a large radius 5 Install the Rear Blade following the above steps in reverse order then adjust the squeegee as necessary To Reverse or Replace the Front Squeegee Blade 1 Raise the squeegee tool off the floor then loosen the two Thumb Nuts on top of the squeegee and remove the squeegee tool from the Squeegee Mount Weldment 2 Remove both Tension Straps then remove the Wing Nuts...

Page 158: ...e floor evenly across its entire width To Adjust the Squeegee Blade Height Adjust the squeegee height whenever a blade is reversed or replaced or if the squeegee is not wiping the floor dry The squeegee blade height is easily adjustable at the caster wheels To adjust the squeegee blade height 1 Park the machine on a flat even surface and lower the squeegee 2 Drive the machine forward enough to hav...

Page 159: ...r power cord adapter to change the motor rotation when setting the correct actuator drive nut dimensions Service Note You can use the above actuator power cord adapter to help position the drive nut spring housing assembly in or out for ease in actuator motor installations Actuator Drive Nut Adjustment 1 Hold onto the Actuator Drive Nut and press the rocker switch on the actuator power cord adapte...

Page 160: ...roubleshooting Problem Cause Correction Problem Cause Solution Poor water pick up Clogged vacuum hose Check the vacuum hose and clear clean as necessary Vacuum leaks Check the squeegee tool and vacuum hose for leaks or cracks and repair replace as necessary The squeegee tilt and or height is set incorrectly Adjust the squeegee tilt and or height as necessary The squeegee leaves narrow streaks of w...

Page 161: ...hine harness 6 Go underneath the machine and remove the two Hair Cotter Pins then slide out push both Clevis Pins from their mounting holes to remove the lift actuator from the machine Note New replacement lift actuator motors do not come with the lift drive nut pre adjusted Service Note After removing the lift actuator and before installing a new actuator or drive nut the drive nut and limit swit...

Page 162: ...st 0 lbs Speed 39 in min 1 4 Amps max Full Load Thrust 600 lbs Speed 30 in min 6 7 1 Amps Start Thrust 600 lbs Shop Measurements Shop measurements are values that were measured on a real machine While they are not specifications they can help you recognize normal vs abnormal Squeegee Actuator Motor Current draw going up 2 2 Amps Current draw going down 1 2 Amps Special Tools Actuator Power Cord Ad...

Page 163: ...ers the steering wheel rotation through the steering shafts and universal joint to the Steer Sprocket at the bottom of the assembly The Steer Sprocket runs a chain connected to the front spindle weldment to turn the drive wheel left and right P clamp Chain Screw 4 Steer Sprocket Bearing Dust Cap Cotter Pin Castle Nut Screw 6 Steer Sprocket ...

Page 164: ...y switch is off the key is removed from the machine and the parking brake is engaged Steering Chain Removal and Tensioning 1 Turn the master key switch off and disconnect the battery pack emergency stop battery disconnect 2 Loosen the four Screws from underneath the front of the machine and push the Lower Steering Column toward the rear of the machine This will allow you to separate the Chain from...

Page 165: ...ring System 165 Service Manual SC6500 Service Note Use a pry bar or shims between the chassis and steer column to help secure the tension adjustment when tightening the four steering column mounting Screws ...

Page 166: ...ed automatically when the scrub system is enabled Note that this automatic side broom function can be enabled or disabled in the main control programming options The broom motors will switch on when the drive pedal is moved from the neutral position Side Broom Sweep System Wiring Diagram A2 Control Board Assembly A3 Switch Display Panel Assembly Fuse 250 A 36V Battery A1 Speed Controller Motion 8 ...

Page 167: ...ich switches the polarity to move the side brooms up or down When the A2 Control Board Assembly receives a signal from the A3 Switch Display Panel Assembly via the CAN BUS that the operator has pressed the scrub on switch the A2 Control Board Assembly sends the appropriate voltage to the Side Broom Actuator M4 to lower the side brooms to the operating position Component Locations The Side Broom As...

Page 168: ... side broom on down and scrub off switches 3 While holding the switches turn the key switch on 4 Continue to hold the switches until the side broom on down indicator scrub off indicator and both scrub on indicators turn on 5 Release the switches The indicators will stay on and the display will now show the side broom actuator down run time in seconds 6 Press the scrub on switch to increase the sid...

Page 169: ...pter red clip to the positive and black to negative to battery connector or battery posts Use the rocker switch on the actuator power cord adapter to change the motor rotation when setting the correct actuator drive nut dimensions Service Note You can use the above actuator power cord adapter to help position the drive nut spring housing assembly in or out for ease in actuator motor installations ...

Page 170: ...cm 3 1 8 7 93cm Cylindrical w side brooms 5 If the OUT measurement doesn t match the dimension shown in the table remove the Adjuster Cover and adjust the OUT position as follows To increase the travel of the Actuator Drive Nut turn the adjuster clockwise To decrease the travel of the Actuator Drive Nut turn the adjuster counterclockwise Note Use a 1 2 13 mm socket to turn the adjuster Each click ...

Page 171: ...und error code 37 displayed 1 Disconnect the K6 coil wiring wire colors VIO and BRN BLK and check to see if the code disappears If the code disappears replace the K6 contactor If the code does reappear test the wiring for a short back to the battery ground Repair or replace the defective wire 2 If the above test doesn t remove the code substitute a new A2 control board assembly The side brooms wil...

Page 172: ...ounts Service Note It may be helpful to lift up and down on the Lift Arm to relieve any preload pressure on the Clevis Pins when removing the front Clevis Pin 4 Drop the Side Broom Lift Actuator out from underneath the machine to remove it Note New replacement lift actuator motors do not come with the lift drive nut pre adjusted Service Note After removing the lift actuator and before installing a...

Page 173: ... Broom Bracket Weldment 4 Install the Side Broom Motor by following the above steps in reverse order 5 Note that the position of the mounting screws inside the three Die Springs set the spring tension for the side broom front and side impact breakaway Once you ve reinstalled the Gearmotor Assembly adjust the mounting screws inside the Die Springs to the dimensions shown in the detail drawing above...

Page 174: ...0 lbs Speed 39 4 in min 1 4 Amps max Full Load Thrust 600 lbs Speed 30 3 in min 6 7 1 Amps Start Thrust 600 lbs Shop Measurements Shop measurements are values that were measured on a real machine While they are not specifications they can help you recognize normal vs abnormal Side Broom Contactor K6 Resistance at room temperature 93 ohms Side Broom Motor Current draw for one motor with no load bro...

Page 175: ...Sweep System Side Broom 175 Service Manual SC6500 Special Tools Actuator Power Cord Adapter p n 56407502 ...

Page 176: ...attached to the brake Spindles and are held on the frame shafts by a M10 1 5 x 20mm hex screw and washer The Brake Pedal Assembly actuates the Brakes via a Cable Assembly The Brake Pedal Assembly can be locked with the Brakes engaged to act as a parking brake The Cable Assembly actuates an Equalizer that ensures the tension from the Cable Assembly is applied equally to both brakes Non traction Whe...

Page 177: ...ke cable Anchor Nuts so approximately 3 8 10mm of the threads is exposed as shown then tighten Anchor Nuts 3 Install a new Tie Strap to the chassis as a cable guide Allow a small amount of cable movement through the Tie Strap There should be about 1 2 of clearance between the Tie Strap and the chassis as shown 4 Check that the left rear brake housing threaded end is about flush with the end of the...

Page 178: ...t against the front slot on the caliper 1 Loosen the large outer Locknut 2 Insert a flat 0 035 0 89 mm feeler gauge between one of the brake pads and the brake disc 3 Loosen the locknut then turn the inner caliper Adjustment Screw in until the pad is lightly touching the feeler gauge 4 Tighten the Locknut 5 After making the adjustment make sure the machine can be pushed easily when the brake pedal...

Page 179: ... is stretched to the point where it cannot be adjusted to provide good braking performance replace the brake cable assembly Adjust the brake caliper to compensate for pad wear Refer to the Brake Caliper Pad Wear Adjustment section If the brake pads are worn to the point where the brake calipers cannot be adjusted to provide good braking performance replace the brake pads Contamination on the brake...

Page 180: ...e cable casing Anchor Nuts and pull the cable free from its mount bracket on the chassis 4 Locate a plastic Tie Strap on the lower left side of the chassis at midpoint then cut the Tie Strap to free the cable at that point 5 Unclip the cable Clevis Yoke at the left brake caliper at the arm and separate 6 Loosen the cable Anchor Locknuts at the Equalizer Yoke mounting bracket The cable assembly is ...

Page 181: ...assembly off the axle 6 If you are replacing the wheel a Remove the four M10 1 5 x 30mm Hex Screws and nuts holding the Brake Rotor to the Rear Wheel hub b Reattach the salvaged Brake Rotor to the new Rear Wheel hub 7 To reinstall the wheel and brake assembly a Place the brake caliper onto the rotor Adjust the gap between the pads and the rotor to 0 035 0 89mm using a feeler gauge See Brake Calipe...

Page 182: ...is spring loaded in the neutral position The drive pedal position sensor is a potentiometer mounted on the side of the pedal that tracks the pedal position The sensor is pre adjusted and comes with the pedal assembly Wheel Drive Controller The wheel drive controller is a self contained sealed unit It controls when and how the current flows to the stator windings to rotate the motor based primarily...

Page 183: ...o simulate a magnetic field moving around the outer perimeter of the motor This moving magnetic field acts upon the armature causing it to rotate An encoder inside the drive wheel motor serves as the eyes of the wheel drive controller so that it can see if the motor turned in the direction that it was trying to move it and how fast it is moving The encoder is a solid state sensor which converts mo...

Page 184: ...e controller The controller must receive a positive voltage on the interlock circuit X6 9 before it will engage the motor The interlock circuit is supplied through the seat switch and the battery interlock switch If either of these is open it will disable the wheel drive motor for safety purposes Note The battery interlock switch is only used when the machine is equipped with a single large mono b...

Page 185: ...perator can also request reduced torque and speed on slippery surfaces using the traction control switch Potentiometer The drive pedal has a three wire potentiometer attached to its side The potentiometer tracks the angle or position of the drive paddle The A1 Wheel drive controller supplies a 5 volt potential across the resistive strip of the potentiometer on the POT high and POT low wires The PO...

Page 186: ...ransistor switches that open and close as the magnetic ring rotates Each switch is provided a 5 volt supply from the controller through a resistor The controller monitors the voltage between the internal resistor and the encoder switch When the switch is open the input is 5v or high When the switch closes the input is 0v or low Phase A input 5V B Wheel Drive Controller Encoder Phase B input 5V Pow...

Page 187: ...al SC6500 Component Locations Drive Wheel Assembly Wheel Drive Controller Drive Pedal with potentiometer Seat Switch S2 Battery Interlock Switch S3 Wheel Drive Controller Drive Pedal Seat Switch Drive Wheel Assembly Battery Interlock Switch ...

Page 188: ...ith the drive system the first thing you should do is check for fault codes Fault codes can be obtained by counting the flash out code of the detergent LED counting the flash code of the Status LED on the wheel drive controller or by using a Curtis hand held programmer 1 Counting the detergent LED flash code a The codes consist of two digits The LED flashes the first digit followed by a short paus...

Page 189: ...to the programmer connector located in the electrical panel by the bank of contactors Refer to a Curtis industries operator s manual for the programmer you are using for more information Summary of LED display formats The status LED has four different display modes indicating the type of information they are providing Types of LED Display Display Status Neither LED illuminated Controller is not po...

Page 190: ... short of phase U V or W motor connections 2 Motor parameters are mis tuned 3 Controller defective 4 Speed encoder noise problems Set Phase current exceeded the current measurement limit Clear Cycle KSI 13 Current Sensor Fault ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump 1 Leakage to vehicle frame from phase U V or W short in motor stator 2 Controller...

Page 191: ... contactor did not close Set Capacitor bank voltage dropped below the Severe Undervoltage limit with FET bridge enabled Clear Bring capacitor voltage above Severe Undervoltage limit 18 Severe Overvoltage ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle FullBrake ShutdownPump 1 See Monitor menu Battery Capacitor Voltage 2 Battery menu parameters are misadjusted 3 Battery resista...

Page 192: ...n Fault shows that regen braking currents elevated the battery voltage during regen braking Controller is performance limited at this voltage 2 Battery parameters are misadjusted 3 Battery resistance too high for given regen current 4 Battery disconnected while regen braking 5 See Monitor menu Battery Capacitor Voltage Set Capacitor bank voltage exceeded the Overvoltage limit with the FET bridge e...

Page 193: ...eter setting Clear Bring the motor temperature within range 29 Motor Temp Sensor Fault MaxSpeed reduced LOS Limited Operating Strategy and motor temperature cutback disabled 1 Motor thermistor is not connected properly 2 If the application doesn t use a motor thermistor Motor Temp Sensor Enable should be programmed Off 3 See Monitor menu Motor Temperature and Inputs Analog2 Set Motor thermistor in...

Page 194: ...Bad crimps or faulty wiring Set Driver 4 pin 3 is either open or shorted Clear Correct open or short and cycle driver 35 PD Open Short ShutdownPD 1 Open or short on driver load 2 Dirty connector pins 3 Bad crimps or faulty wiring Set Proportional driver pin 2 is either open or shorted Clear Correct open or short and cycle driver 36 Encoder Fault ShutdownEMBrake ShutdownThrottle 1 Motor encoder fai...

Page 195: ...igh fault threshold can be changed with the VCL function Setup_ Pot_Faults Clear Bring throttle pot wiper voltage below the fault threshold 42 Throttle Wiper Low ShutdownThrottle 1 See Monitor menu Inputs Throttle Pot 2 Throttle pot wiper voltage too low Set Throttle pot wiper pin 16 voltage is lower than the low fault threshold can be changed with the VCL function Setup_ Pot_Faults Clear Bring th...

Page 196: ...orrect sequence 2 Faulty wiring crimps or switches at KSI interlock direction or throttle inputs 3 See Monitor menu Inputs Set HPD High Pedal Disable or sequencing fault caused by incorrect sequence of KSI interlock direction and throttle inputs Clear Reapply inputs in correct sequence 47 Emer Rev HPD ShutdownThrottle ShutdownEMBrake 1 Emergency Reverse operation has concluded but the throttle for...

Page 197: ...xternal load on the 5V and 12V supplies draws either too much or too little current 2 Fault Checking Menu parameters Ext Supply Max and Ext Supply Min are mis tuned 3 See Monitor menu Outputs Ext Supply Current Set The external supply current combined current used by the 5V supply pin 26 and 12V supply pin 25 is either greater than the upper current threshold or than the lower current threshold Th...

Page 198: ...visor Fault ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle ShutdownInterlock ShutdownDriver1 ShutdownDriver2 ShutdownDriver3 ShutdownDriver4 ShutdownPD FullBrake ShutdownPump 1 The Supervisor has detected a mismatch in redundant readings 2 Internal damage to Supervisor microprocessor 3 Switch inputs allowed to be within upper and lower thresholds for over 100 milliseconds Set...

Page 199: ...encoder signal not seen or one both channels missing 9 motor parameters out of characterization range Set Motor characterization failed during the motor characterization process Clear Correct fault cycle KSI 88 Encoder Pulse Error ShutdownMotor ShutdownMainContactor ShutdownEMBrake ShutdownThrottle ShutdownInterlock ShutdownDriver1 ShutdownDriver2 ShutdownDriver3 ShutdownDriver4 ShutdownPD FullBra...

Page 200: ... has been activated a result of either an Encoder Code 36 or a Stall Detect Code 73 2 Motor encoder failure 3 Bad crimps or faulty wiring 4 Vehicle is stalled Set Encoder Fault Code 36 or Stall Detect Fault Code 73 was activated and Brake or Interlock has been applied to activate LOS control mode allowing limited motor control Clear Cycle KSI or if LOS mode was activated by the Stall Fault clear b...

Page 201: ...e manual Fault History The 1313 programmer can be used to access the controller s fault history file The programmer will read out all the faults the controller has experienced since the last time the fault history file was cleared Faults such as contactor faults may be the result of loose wires contactor wiring should be carefully checked Faults such as over temperature may be caused by operator h...

Page 202: ... spindle assembly to service the drive tire only Warning Turn the key switch off and disconnect the battery pack Engage the machine parking brake and block both rear wheels so machine can t roll Never work under machine without safety stands or blocking to support the machine 1 Jack up the front of the vehicle so that the front wheel is off the ground and support the vehicle safely on jack stands ...

Page 203: ... extractor screws in the casting threaded holes as shown and turn them in until each screw touches the rim of the tire Then turn all of them evenly in small increments until the wheel is pushed off the support bearing b Remove puller screws Threaded holes for puller screws 4 Remove 10 fasteners around the perimeter of the drive wheel hub and separate the drive wheel hub from the wheel tire ...

Page 204: ...o 20 22 Nm 16 ft lb 2 Lightly install the two alignment pins from the tire puller kit into two of the threaded holes of the gearbox hub flange 3 Slide the drive hub with the wheel tire over the alignment pins 4 Apply loctite 243 or equivalent to the 4 hub center fasteners Remove the alignment pins and install the 4 fasteners 5 In small increments simultaneously tighten all four screws Torque to 75...

Page 205: ...ly on jack stands 3 Turn the wheel so that the motor is facing forward 4 Remove the two screws securing the plastic cover over the motor cable connections and remove the cover 5 Mark the U V and W cables for correct reassembly Disconnect the small motor sensor connector 6 Disconnect the U V and W cables from the motor using a back up wrench on the nut behind the cable to prevent the stud from rota...

Page 206: ...ches 20 25 cm from the center bottom edge of the solution tank 12 Carefully guide the wheel motor assembly down and out of its frame opening Tilt the wheel motor assembly to the side while raising the machine then pull it out from underneath the machine Note Be careful not to damage the threads and bearing surfaces when dropping the spindle shaft down through the frame when removing it from the ch...

Page 207: ...eutral Adjustment and Pedal Replacement The drive pedal comes with the potentiometer attached and pre adjusted However if the potentiometer position on the pedal changes it can be adjusted 1 Block the rear wheels and jack the front wheel up off the floor 2 Back probe the potentiometer throttle wiper input signal wire at the Speed Controller with your red voltmeter lead 3 Back probe the pot low wir...

Page 208: ...es to their respective controller lugs 5 Disconnect the low current connector 6 Remove controller attaching screws and remove the controller 7 Reassemble in reverse order When attaching cables use the correct hardware in the correct order to avoid damage caused from a loose connection Torque to 90 IN LBS 10 17 Nm Figure 14 Damaged Controller lug from loose connection Case removed for clarity Figur...

Page 209: ...Traction 209 Service Manual SC6500 Speed Mode Table Mode 1 Pin 10 Mode2 Pin 11 Effect Low 0V Low 0V Transport Mode Mode 1 High 19V Low 0V Scrub Mode Mode 2 Low 0V High 19V Traction Mode Mode 3 High 19V High 19V N A ...

Page 210: ...gic power for the controller and power for the coil drivers 37 67 V 2 Not Used 3 ORN RED Fault Curtis Driver 4 34 37 V with no current faults 4 YEL RED Direction Curtis Driver 3 34 37 V Forward or Stationary 0 004 V Reverse 5 RED WHT Motion Curtis Driver 2 25 85 V Stationary 0 005 V Moving Forward or Reverse 6 BLK YEL K7 Main Contactor Driver Curtis Driver 1 37 7 V key on contactor off When seat s...

Page 211: ... 22 Not Used 23 Not Used 24 Not Used 25 VIO WHT Unregulated low power 12 V output Power for Programmer Connector 12 99 V 26 PINK RED Regulated low power 5v output 5 03 V 27 Not Used 28 WHT ORN Serial Transmit for Programmer Connector 0 11 V 29 BLU GRN Serial Receive for Programmer Connector 0 002 V Momentary jump to 4 V when programmer is connected 30 Not Used 31 PINK WHT Drive Motor Encoder Signa...

Page 212: ...d Controller Current Draw Measured with amp clamp around battery negative feed to wheel drive controller Key on 0 40 Amps DC Full forward speed wheel off ground 5 9 Amps DC Transport Heavy acceleration up to around 68 Amps DC Maintain full forward speed on level floor around 30 Amps DC Main Contactor K7 Winding resistance at room temperature 100 ohms ...

Page 213: ...d held programmer model 1311 1101 part number 56409441 Curtis hand held programmer model 1313 1101 part number 56383571 Tire Puller Kit 56422174 Consists of threaded screws to push the wheel off the bearing and pilot studs for aligning drive hub threads during installation ...

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