EZ Rider HPt *330825* Service Information Rev. 00. The safe scrubbing alternativet. Patents Pending

Transcription

1 EZ Rder HPt Servce Informaton Patents Pendng The safe scrubbng alternatvet 085 Rev. 00 *085*

2 Ths manual provdes servce nformaton for the NOBLES Model EZ Rder HP. Ths machne wll provde excellent servce. However, the best results wll be obtaned at mnmum costs f: D D D The machne s operated wth reasonable care. The machne s mantaned regularly -- per the mantenance nstructons provded. The machne s mantaned wth NOBLES suppled or equvalent parts. Manual Number Revson: 00 Publshed: --05 FaSTt and The safe scrubbng alternatvet are Unted States trademarks of Tennant Company. Copyrght E 005 NOBLES, Prnted n U.S.A.

3 EZ Rder HP ELECTRICAL Troubleshootng Informaton BEFORE CONDUCTING TESTS: * Read and Follow ALL Safety Warnngs and Precautons n Operator's Manual * Always use an ESD (Electrostatc Dscharge) strap when workng near the Control Board * Be cautous when workng near Control Board Battery voltage s always present, even wth Key OFF * Always unplug Battery Connector when removng or replacng components DURING TESTS: * Call Techncal Servces f Dagnostc Tme Exceeds One Hour Wth Unknown Cause or Course of Acton NOTE:Troubleshootng charts may be shown wth optonal equpment. The optonal equpment may not be specfed n these charts. Some machnes may not be equpped wth all components shown EZHPETI REV 00

4 DESCRIPTION Table of Contents PAGE(S) Electrcal Schematc ( ) Electrcal Schematc (00- ) Electrcal Schematc for Models wth On-board Charger Electrcal Schematc Addendum for Models wth FaST System Wre Harness Drawngs ( ) Wre Harness Drawngs (00- ) Wre Harness Drawngs Addendum for Models wth FaST System Commonly Used Electrcal Symbols & Terms Troubleshootng Sub-system Dagrams (Breakout Schematcs) Key Swtch & Seat Swtch Emergency Stop Swtch Propel System Scrub Brush Motors Scrub & Brush Pressure Swtches Scrub Mode Swtch Scrub Head Confguraton Connecton Vacuum Fan Motor Recovery Tank Level Swtches Extended Scrub (ES) System FaST System Sgnal Resstor (FaST Only) Squeegee Actuator Scrub Head Actuator Scrub Head Actuator Removal & Installaton Instructons Horn, Back-up Alarm, & Hazard Lght Systems Soluton Flow Control Fuses & Crcut Breakers Machne Controller (Tro) Informaton Troubleshootng Flowcharts Pn Confguratons Pn Inputs & Outputs Battery Cable Connectons Battery Dscharge Indcator (BDI) Informaton FaST System Informaton Troubleshootng Flowcharts Test Ponts (Chart # ) Specfcatons (Chart # ) On-board Charger Setup Instructons

5 EZ Rder HP Electrcal Schematc ( ) NOT USED SEAT SWITCH FAULT NOT USED /GRY

6 EZ Rder HP Electrcal Schematc (00 - ) NOT USED SEAT SWITCH FAULT NOT USED /GRY

7 EZ Rder HP Electrcal Schematc for Models wth Optonal On-board Charger DIAGNOSTIC LED FAULT CODES DIAGNOSTIC MESSAGE: NUMBER OF BARS FLASHING = LOW BATTERY VOLTAGE = TRACTION MOTOR FAULT = BRUSH MOTOR FAULT = ONE FLASH = SCRUB HEAD ACTUATOR FAULT TWO FLASH = SQUEEGEE ACTUATOR FAULT 5= VACUUM MOTOR FAULT = SEAT SWITCH OPEN = ONE FLASH = THROTTLE FAULT TWO FLASH = IMPUT SWITCH FAULT 8= CONTROL SYSTEM FAULT 9= ONE FLASH = RECOVERY TANK FULL SENSOR FAULT TWO FLASH = BACK UP ALAM FAULT THREE FLASH = SOLUTION VALVE FAULT FOUR FLASH = ES PUMP FAULT FIVE FLASH = HOUR METER FAULT 0 = HIGH BATTERY VOLTAGE RIPPLE UP/ON = PEDAL NOT IN NEUTRAL FUSE #9895 FUSE #99 I FUSE #99 FUSE #99 FU- FUSE #99 FUSE #99 ON--BOARD CHARGER (OPTION) (0--05)

8 EZ Rder HP Electrcal Schematc Addendum for Models wth FaST System

9 EZ Rder HP Wre Harnesses Group ( ) Page of 5

10 EZ Rder HP Wre Harnesses Group ( ) Page of

11 EZ Rder HP Wre Harnesses Group ( ) Page of

12 EZ Rder HP Wre Harnesses Group ( ) Page of ) 8

13 EZ Rder HP Wre Harnesses Group (00 - ) Page of 9

14 EZ Rder HP Wre Harnesses Group (00 - ) Page of 0

15 EZ Rder HP Wre Harnesses Group (00 - ) Page of

16 EZ Rder HP Wre Harnesses Group (00 - ) Page of 5

17 EZ Rder HP Wre Harnesses Group Addendum for Models wth FaST System Page of

18 EZ Rder HP Wre Harnesses Group Addendum for Models wth FaST System Page of

19 Commonly Used Electrcal Symbols & Terms NOTE: The term NORMALLY refers to the component s at rest or de-energzed poston Wres Connected Together Wres t Connected Together Plug-n Connecton Battery Chasss Ground (Statc Dran) rmally Open Swtch rmally Closed Seat Swtch rmally Closed Lmt Swtch rmally Open Push-Button Swtch rmally Closed Push-Button Swtch rmally Open Lqud Level Swtch rmally Open Pressure Swtch Crcut Breaker Fuse Hour Meter MA Motor Solenod Valve Lamp (Lght Bulb) Horn or Alarm Relay Col wth spke suppresson dode Open Closed Relay Contacts! Potentometer (Varable Resstor) Fxed value resstor Dode LED Informaton Warnng! Component s Energzed Movement from rmal Poston Component n Poston Other than rmal Informaton Box Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Example of Wrng Numbers & Colors: Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte Assembly Battery Postve or Postve Output Terms & Abbrevatons Battery Negatve or Logc Ground BDI Battery Dscharge Indcator LED Lght Emttng Dode PWM (Pulse Wdth Modulaton) A method of usng controlled on/off tmes to regulate the voltage and current suppled to an electrcal devce RED 5 BLK Output that can Change Polarty 5

20 EZ Rder HP - Key OFF VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER! RED BATTERY VOLTAGE PRESENT AT ALL TIMES FU- 5 A + POS NEG - BLK KEYSWITCH FU-5 0 A PIN P-8 PIN P- BDI STATIC DRAIN (Connected to metal frame of machne) SWITCHED GROUND PIN P-9 PIN P-8 Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte! Be cautous when workng near Control Board Battery voltage s always present, even wth Key OFF

21 EZ Rder HP - Key ON, Operator on Seat VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED FU- 5 A + POS NEG - BLK KEYSWITCH FU-5 0 A PIN P-8 SIGNAL OUTPUT PIN P- BDI STATIC DRAIN (Connected to metal frame of machne) SWITCHED GROUND PIN P-9 PIN P-5 SEAT SWITCH PIN P-8 VDC Wth Key ON Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte BDI should dsplay the state of charge of the batteres f no faults are found; Refer to Machne Controller troubleshootng f BDI LED s are flashng

22 EZ Rder HP - Key ON, Operator NOT on Seat VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED FU- 5 A + POS NEG - BLK KEYSWITCH FU-5 0 A PIN P-8 SIGNAL OUTPUT PIN P- BDI STATIC DRAIN (Connected to metal frame of machne) SWITCHED GROUND PIN P-9 PIN P-5 SEAT SWITCH PIN P-8 VDC Wth Key ON Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte BDI should dsplay rapdly flashng LED s, ndcatng that the operator s not sttng on seat; Refer to Machne Controller troubleshootng for more nformaton 8

23 EZ Rder HP Emergency Stop Swtch CONDITIONS: Key ON VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED FU- 5 A + POS NEG - BLK KEYSWITCH FU-5 0 A PIN P-8 SIGNAL OUTPUT PIN P- BDI STATIC DRAIN (Connected to metal frame of machne) SWITCHED GROUND PIN P-9 PIN P-8 PIN P- PIN P-9 5 SIGNAL INPUT 0VDC REFERENCE EMERGENCY STOP SWITCH VDC Wth Key ON Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte Emergency Stop Swtch s normally closed; Actvatng the Emergency Stop Swtch opens the swtch and removes the 0VDC reference voltage to PIN P- Machne wll functon normally f a 0VDC reference voltage s sensed at pn P- All machne functons wll shut off f no reference voltage s sensed at pn P- If the Emergency Stop Swtch has been actvated, the BDI should dsplay 8 rapdly flashng LED s; Refer to Machne Controller troubleshootng for more nformaton 9

24 EZ Rder HP Propel System CONDITIONS: Key ON, operator on seat & travel (forward or reverse) VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED FU- 5 A + POS NEG - BLK A BLK A BLK KEYSWITCH FU-5 0 A SIGNAL OUTPUT PIN P-8 PIN P- TRACTION A WHT HOUR METER 5 5 BDI STATIC DRAIN (Connected to metal frame of machne) SWITCHED GROUND PIN P-9 PIN P-8 PIN P-9 A WHT 8 0VDC REFERENCE *PWM* PROPEL MOTOR A BLK PIN P-0 9 THROTTLE SIGNAL INPUT VDC Wth Key ON PIN P-0 0 5VDC REFERENCE.5K Ohm (+/- 0%) Potentometer Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte! Dsconnect Tracton connector when testng Foot Throttle Potentometer or voltage output to Propel Motor FOOT THROTTLE POTENTIOMETER Typcal Propel Motor Current Draw: to 5 Amps n moton, hgher at start-up Maxmum NO-LOAD current: Amps (wheel rased off floor) Maxmum current allowed to Propel Motor by controller: Amps Propel Motor Voltage: 0 to VDC - FORWARD 0 to approx. VDC - REVERSE Propel Motor s controlled by PWM (Pulse Wdth Modulaton) Throttle Sgnal Input wll vary from approxmately 0 to 5VDC as propel pedal s moved from full forward to full reverse, wth neutral beng approxmately.5vdc 0

25 EZ Rder HP Scrub Brush Motors CONDITIONS: Key ON, operator on seat, forward travel, One Step swtch ON, scrub mode swtch n scrub only or scrub & vacuum poston VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED FU- 5 A + POS NEG - BLK KEYSWITCH FU-5 0 A PIN P-8 SIGNAL OUTPUT PIN P- BRUSH WHT WHT BDI STATIC DRAIN (Connected to metal frame of machne) SWITCHED GROUND PIN P-9 LEFT BRUSH MOTOR PIN P-8 WHT VDC Wth Key ON RIGHT BRUSH MOTOR Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte REVERSING WIRE HARNESS FOR CYLINDRICAL SCRUB HEAD LOCATED AT & CONNECTED TO REAR SCRUB BRUSH MOTOR Maxmum Brush Motor Current Draw: Standard-duty DISC brush motors 5 Amps Maxmum EACH Heavy-duty DISC brush motors Amps Maxmum EACH CYLINDRICAL brush motors Amps Maxmum EACH A reversng wre harness s used to change the drecton of one motor on machnes equpped wth a CYLINDRICAL scrub head (see dagram above)

26 EZ Rder HP Scrub & Brush Pressure Swtches (rmal Brush Pressure) CONDITIONS: Key ON, operator on seat, forward travel, One Step swtch ON, scrub mode swtch n scrub only or scrub & vacuum poston VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED FU- 5 A + POS NEG - BLK KEYSWITCH FU-5 0 A PIN P-8 PIN P- PIN P- SIGNAL INPUT ONE STEP SWITCH BDI STATIC DRAIN (Connected to metal frame of machne) SIGNAL OUTPUT SWITCHED GROUND PIN P- PIN P-9 PIN P-8 PIN P- PIN P-9 5VDC REFERENCE 0VDC REFERENCE NORMAL HEAVY BRUSH PRESSURE SWITCH VDC Wth Key ON Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte rmal brush pressure wll be appled f a 5VDC reference voltage s sensed at pns P- and P- Heavy brush pressure wll be appled f a 0VDC reference voltage s sensed at pns P- and P- Scrub Functons wll be dsabled f NO reference voltage s sensed at pns P- and P-

27 EZ Rder HP Scrub & Brush Pressure Swtches (Heavy Brush Pressure) CONDITIONS: Key ON, operator on seat, forward travel, One Step swtch ON, scrub mode swtch n scrub only or scrub & vacuum poston VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED FU- 5 A + POS NEG - BLK KEYSWITCH FU-5 0 A PIN P-8 PIN P- PIN P- SIGNAL INPUT ONE STEP SWITCH BDI STATIC DRAIN (Connected to metal frame of machne) SIGNAL OUTPUT SWITCHED GROUND PIN P- PIN P-9 PIN P-8 PIN P- PIN P-9 5VDC REFERENCE NORMAL 0VDC REFERENCE HEAVY BRUSH PRESSURE SWITCH VDC Wth Key ON Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte rmal brush pressure wll be appled f a 5VDC reference voltage s sensed at pns P- and P- Heavy brush pressure wll be appled f a 0VDC reference voltage s sensed at pns P- and P- Scrub Functons wll be dsabled f NO reference voltage s sensed at pns P- and P-

28 EZ Rder HP Scrub Mode Swtch (Scrub & Vacuum) CONDITIONS: Key ON, operator on seat, forward travel, One Step swtch ON VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED FU- 5 A + POS NEG - BLK KEYSWITCH FU-5 0 A PIN P-8 PIN P- SIGNAL INPUT BDI STATIC DRAIN (Connected to metal frame of machne) SIGNAL OUTPUT SWITCHED GROUND PIN P- PIN P-9 PIN P-8 PIN P- PIN P-9 5VDC REFERENCE X 0VDC REFERENCE VACUUM ONLY SCRUB ONLY SCRUB & VACUUM SCRUB MODE SWITCH VDC Wth Key ON Swtch Poston Scrub & Vacuum Reference Voltage to P- 5VDC System Functons All scrub, vacuum, & squeegee operatons Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte Vacuum Only Scrub Only NONE 0VDC Vacuum & Squeegee operatons only scrubbng Scrub operatons only vacuum or squeegee operatons Scrub system and Vacuum/Squeegee system wll operate f a 5VDC reference voltage s sensed at pn P- Vacuum/Squeegee system ONLY wll operate f NO reference voltage s sensed at pn P- (Default state) Scrub system ONLY wll operate f a 0VDC reference voltage s sensed at pn P-

29 EZ Rder HP Scrub Mode Swtch (Vacuum Only) CONDITIONS: Key ON, operator on seat, forward travel, One Step swtch ON VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED FU- 5 A + POS NEG - BLK KEYSWITCH FU-5 0 A PIN P-8 PIN P- SIGNAL INPUT BDI STATIC DRAIN (Connected to metal frame of machne) SIGNAL OUTPUT SWITCHED GROUND PIN P- PIN P-9 PIN P-8 PIN P- PIN P-9 5VDC REFERENCE X 0VDC REFERENCE SCRUB & VACUUM VACUUM ONLY SCRUB ONLY SCRUB MODE SWITCH VDC Wth Key ON Swtch Poston Scrub & Vacuum Reference Voltage to P- 5VDC System Functons All scrub, vacuum, & squeegee operatons Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte Vacuum Only Scrub Only NONE 0VDC Vacuum & Squeegee operatons only scrubbng Scrub operatons only vacuum or squeegee operatons Scrub system and Vacuum/Squeegee system wll operate f a 5VDC reference voltage s sensed at pn P- Vacuum/Squeegee system ONLY wll operate f NO reference voltage s sensed at pn P- (Default state) Scrub system ONLY wll operate f a 0VDC reference voltage s sensed at pn P- 5

30 EZ Rder HP Scrub Mode Swtch (Scrub Only) CONDITIONS: Key ON, operator on seat, forward travel, One Step swtch ON VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED FU- 5 A + POS NEG - BLK KEYSWITCH FU-5 0 A PIN P-8 PIN P- SIGNAL INPUT BDI STATIC DRAIN (Connected to metal frame of machne) SIGNAL OUTPUT SWITCHED GROUND PIN P- PIN P-9 PIN P-8 PIN P- PIN P-9 5VDC REFERENCE X 0VDC REFERENCE SCRUB & VACUUM VACUUM ONLY SCRUB ONLY SCRUB MODE SWITCH VDC Wth Key ON Swtch Poston Scrub & Vacuum Reference Voltage to P- 5VDC System Functons All scrub, vacuum, & squeegee operatons Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte Vacuum Only Scrub Only NONE 0VDC Vacuum & Squeegee operatons only scrubbng Scrub operatons only vacuum or squeegee operatons Scrub system and Vacuum/Squeegee system wll operate f a 5VDC reference voltage s sensed at pn P- Vacuum/Squeegee system ONLY wll operate f NO reference voltage s sensed at pn P- (Default state) Scrub system ONLY wll operate f a 0VDC reference voltage s sensed at pn P-

31 EZ Rder HP Scrub Head Confguraton Connecton CONDITIONS: Key OFF to change confguraton settng VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED FU- 5 A + POS NEG - BLK KEYSWITCH FU-5 0 A PIN P-8 PIN P- 5VDC REFERENCE Refer to nformaton below for proper confguraton settng BDI STATIC DRAIN (Connected to metal frame of machne) SWITCHED GROUND PIN P- PIN P-9 PIN P- PIN P-9 8 BRUSH PRESSURE SIGNAL INPUT 0VDC REFERENCE PIN P-8 VDC Wth Key ON Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte Confguraton Settngs: For Standard-duty DISC scrub brush motors: MAKE NO CONNECTIONS For CYLINDRICAL or Heavy-duty DISC scrub brush motors: CONNECT WIRES & 8 (0VDC reference & sgnal nput) For applcatons requrng EXTRA-LIGHT down pressure: CONNECT WIRES & 8 (5VDC reference & sgnal nput)

32 EZ Rder HP Vacuum Fan Motor CONDITIONS: Key ON, operator on seat, One Step swtch ON, scrub mode swtch n vacuum only or scrub & vacuum poston VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED FU- 5 A + POS NEG - BLK KEYSWITCH FU-5 0 A PIN P-8 SIGNAL OUTPUT PIN P- VACUUM BDI STATIC DRAIN (Connected to metal frame of machne) SWITCHED GROUND PIN P-9 VACUUM FAN MOTOR PIN P-8 VDC Wth Key ON Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte Maxmum Vacuum Fan Motor Current Draw: 0 Amps Typcal Vacuum Fan Motor Current Draw: to 8 Amps 8

33 EZ Rder HP Recovery Tank Full Level Swtch CONDITIONS: Key ON VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED KEYSWITCH BDI STATIC DRAIN (Connected to metal frame of machne) FU-5 0 A SIGNAL OUTPUT SWITCHED GROUND FU- 5 A PIN P-8 PIN P- PIN P-9 PIN P-8 + POS NEG - PIN P- PIN - PIN P- PIN P-5 9 FU- 0 A RECOVERY TANK FULL 9 LAMP B 5 SIGNAL INPUT RECOVERY TANK FULL LEVEL SWITCH 0VDC REFERENCE A X C BLK VDC Wth Key ON Orange wre # s found n connector body, but s not used VDC Wth Key ON Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte Recovery Tank Full Swtch closes when recovery tank s full Recovery Tank Full Lamp s lt when recovery tank s full Recovery Tank Full Swtch s n the OPEN poston wth low or empty tank Recovery Tank Full Swtch s n the CLOSED poston wth full tank 9

34 EZ Rder HP Recovery Tank Half Full Level Swtch (ES Only) CONDITIONS: Key ON VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED FU- 5 A + POS NEG - BLK KEYSWITCH FU-5 0 A PIN P-8 Orange wre # s found n connector body, but s not used BDI STATIC DRAIN (Connected to metal frame of machne) SIGNAL OUTPUT SWITCHED GROUND PIN P- PIN P-9 PIN P-8 PIN P- PIN P-5 B SIGNAL INPUT RECOVERY TANK HALF FULL LEVEL SWITCH 0VDC REFERENCE A X C VDC Wth Key ON Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte Recovery Tank Half Full Swtch closes when recovery tank s half full or hgher Recovery Tank Half Full Level Swtch s n the OPEN poston wth low or empty tank Recovery Tank Half Full Level Swtch s n the CLOSED poston wth at least a half full tank If wre # (PIN P-) s grounded or shorted to the 0VDC reference, the Machne Controller wll assume the ES system s nstalled and the recovery tank s at least half full 0

35 EZ Rder HP Extended Scrub (ES) System CONDITIONS: Key ON, operator on seat, recovery tank at least half full VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED KEYSWITCH FU-5 0 A FU- 5 A PIN P-8 + POS NEG - PIN P- 9 FU- 0 A VDC Wth Key ON BLK SIGNAL OUTPUT PIN P- PIN P- BDI STATIC DRAIN (Connected to metal frame of machne) SWITCHED GROUND PIN P-9 PIN P-8 PIN P-5 PIN P- 0VDC REFERENCE 8 SIGNAL INPUT ES PUMP MOTOR 8 BLK VDC Wth Key ON 9 ES SWITCH 0 Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte Recovery Tank must be at least half full for ES pump to operate ES system wll be actve anytme ES Swtch s ON, regardless f scrub system s ON or not ES Pump current draw:. Amps at full load

36 EZ Rder HP FaST System CONDITIONS: Key ON, operator on seat, forward travel, scrub system actve VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED KEYSWITCH FU-5 0 A SIGNAL OUTPUT FU- 5 A PIN P-8 PIN P- + POS NEG - PIN P- PIN P- FU- 0 A 9 B 5 MA 55 A VDC Wth Key ON BLK RED CB- 0 A BDI STATIC DRAIN (Connected to metal frame of machne) Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte VDC Wth Key ON MB SWITCHED GROUND 5 PIN P-9 PIN P-8 MA PIN P-5 PIN P- BLK WATER DETERGENT PUMP PRESSURE 5 SWITCH 5 5 SOLENOID VALVE D 5 WATER PUMP VDC REFERENCE Approxmately 5 pulses per mnute SIGNAL INPUT AIR PUMP TIMER MODULE D x x FaST SWITCH rmally OPEN pressure swtch held closed wth water pressure BLK BLK MB BLK Actvated by Machne Controller

37 EZ Rder HP Sgnal Resstor (FaST Only) CONDITIONS: Key ON VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED KEYSWITCH BDI STATIC DRAIN (Connected to metal frame of machne) FU-5 0 A SIGNAL OUTPUT SWITCHED GROUND FU- 5 A PIN P-8 PIN P- PIN P-9 PIN P-8 + POS NEG - PIN P- PIN P-5 B FaST SIGNAL INPUT Resstor connects to Recovery Tank Half Full connector 5.K OHM RESISTOR A X C 0VDC REFERENCE BLK Orange wre # s found n connector body, but s not used VDC Wth Key ON Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte The 5.K Ohm resstor connected as shown above wll tell the Machne Controller that the FaST system s nstalled If the 5.K Ohm resstor s not nstalled, the Machne Controller wll assume there s no FaST system nstalled and the recovery tank s not at least half full If wre # (PIN P-) s grounded or shorted to the 0VDC reference, the Machne Controller wll assume the ES system s nstalled and the recovery tank s at least half full

38 EZ Rder HP Squeegee Actuator CONDITIONS: Key ON, operator on seat, engage or dsengage One Step swtch wth Vacuum Fan actve VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED FU- 5 A + POS NEG - BLK KEYSWITCH FU-5 0 A PIN P-8 PIN P- RETRACT SIGNAL OUTPUT PIN P- Surge Suppressor (Transent Voltage Suppressor) BDI STATIC DRAIN (Connected to metal frame of machne) SWITCHED GROUND PIN P-9 PIN P-8 PIN P-0 0 TVS EXTEND FU- 0 A VDC Wth Key ON SQUEEGEE LIFT/ LOWER ACTUATOR Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte Squeegee Actuator lmt swtches are both normally closed, and the respectve swtch wll open at the end-of-travel when extendng or retractng Both lmt swtches wll be closed durng actuator travel Dodes are used to allow current flow around the open swtch at the begnnng of actuator movement (untl swtch closes) Squeegee Actuator current draw: 5.0 Amps at full load

39 EZ Rder HP Scrub Head Actuator CONDITIONS: Key ON, operator on seat, engage or dsengage One Step swtch wth scrub system actve VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED FU- 5 A + POS NEG - PIN P- 8 8 D BLK KEYSWITCH FU-5 0 A PIN P-8 SIGNAL OUTPUT PIN P- PIN P- FU- GRY 0 A 9 E BDI STATIC DRAIN (Connected to metal frame of machne) SWITCHED GROUND PIN P-9 PIN P- PIN P- 5 5 C B EXTEND RETRACT VDC Wth Key ON PIN P-8 PIN P-5 0VDC REFERENCE A SCRUB HEAD LIFT/ LOWER ACTUATOR Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte Scrub Head Actuator lmt swtches are both normally closed, and the respectve swtch wll open at the end-of-travel when extendng or retractng Machne controller wll turn OFF Scrub Head Actuator when ether PIN P- or P- no longer receves the 0VDC reference sgnal Both lmt swtches wll be closed durng actuator travel Scrub Head Actuator current draw: 5.0 Amps at full load 5

40 EZ Rder HP Scrub Head Actuator Removal & Installaton DESCRIPTION: Instructons to remove and renstall the scrub head lft actuator on the model EZ Rder HP SPECIAL TOOLS / CONSIDERATIONS: ne (Estmated tme to complete: hour) FIG. - Scrub Head Lft Group IB 050 (-0) Page of 5

41 EZ Rder HP Scrub Head Actuator Removal & Installaton Removal:. Unplug the seat swtch.. Loosen the four bolts holdng actuator plate.. Unplug the tracton plug from the P&G controller. 5. Put the vacuum fan/squeegee swtch nto the vacuum off poston. Put the one--step (scrub) swtch nto the on poston.. Turn the key swtch on and actvate the pedal n the forward drecton. The scrub deck wll begn to lower and the brush motors wll turn on.. Remove the scrub brushes or pad drvers. IB 050 (-0) Page of 5

42 EZ Rder HP Scrub Head Actuator Removal & Installaton. When the scrub deck makes contact wth the floor and begns to rase the actuator plate, turn the power off at the key swtch or by usng the power kll swtch. 8. Remove the four bolts holdng the plate n place.. Unplug the actuator and lft out the assembly..remove the lower bracket assembly. 9. Power on and actvate forward propel untl the actuator reaches full extenson, then power off. 0.Remove the clevs pn at the lower channel. IB 050 (-0) 8 Page of 5

43 EZ Rder HP Scrub Head Actuator Removal & Installaton Installaton:.Lay some cardboard or other non--conductve materal across the batteres and lay the actuator assembly down on t. FOR SAFETY: To prevent shock or sparks, do not lay actuator or metal tools on battery cables..hold onto the tube, power on, actvate forward propel untl the actuator reaches full extenson, then power off. HOLD ON TO THE TUBE ALL THE WAY. If t slps, repeat steps &..Unplug the actuator and renstall the lower bracket.plug the actuator nto the harness, power on and allow the actuator to turn freely untl the upper lmt swtch n the actuator opens and turns the motor off. 5.Power off. Turn the tube by hand untl the gap between the gear--box and tube s mm (/ n). 8.Remove the cardboard and place the actuator back nto poston. 9.Connect the actuator to the machne by nstallng the lower clevs pn. IB 050 (-0) 9 Page of 5

44 EZ Rder HP Scrub Head Actuator Removal & Installaton 0.Start the two rear bolts nto the actuator plate..power on, and allow the actuator to retract and pull the upper plate nto poston. FOR SAFETY: Keep hands clear of pnch ponts whle retractng actuator..install and tghten all four plate bolts and plug n the actuator..plug n the seat swtch and the tracton plug..install scrub brushes or pad drvers. IB 050 (-0) 0 Page 5 of 5

45 EZ Rder HP Horn, Back-up Alarm & Hazard Lght Systems CONDITIONS: Key ON, operator on seat & reverse travel (for back-up alarm) VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED KEYSWITCH BDI STATIC DRAIN (Connected to metal frame of machne) FU-5 0 A SIGNAL OUTPUT SWITCHED GROUND FU- 5 A PIN P-8 PIN P- PIN P-9 PIN P-8 + POS NEG - PIN P- PIN FU- 0 A Pulsed Battery Ground wth Reverse Travel HAZARD LIGHT SWITCH 0 5 VDC Wth Key ON HAZARD LIGHT BLK BACK-UP ALARM BLK VDC Wth Key ON 0 BLK HORN SWITCH HORN Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte Back-up Alarm sounds only durng reverse travel

46 EZ Rder HP Soluton Flow Control ( ) CONDITIONS: Key ON, operator on seat, forward travel, One Step swtch ON, scrub mode swtch n scrub only or scrub & vacuum poston VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED KEYSWITCH FU-5 0 A SIGNAL OUTPUT FU- 5 A PIN P-8 PIN P- + POS NEG - PIN P- Used for conventonal scrubbng ONLY 9 FU- 0 A *PWM* BLK VDC Wth Key ON BDI STATIC DRAIN (Connected to metal frame of machne) SWITCHED GROUND PIN P-9 PIN P-8 PIN P-9 PIN P- PIN P- 5VDC REFERENCE SIGNAL INPUT SOLUTION VALVE VDC Wth Key ON Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte 0VDC REFERENCE Used for conventonal scrubbng ONLY SOLUTION FLOW CONTROL POTENTIOMETER t all machnes use electronc Soluton Flow Control some machnes use a mechancal devce to control the amount of soluton appled to the floor If electronc Soluton Flow Control s used, the Soluton Valve s controlled by Pulse Wdth Modulaton The Soluton Valve and Soluton Flow Control Potentometer s used only durng conventonal scrubbng they are NOT used durng FaST scrubbng Typcal Soluton Valve current draw: 0. to 0.5 Amps

47 EZ Rder HP Soluton Flow Control (00- ) CONDITIONS: Key ON, operator on seat, forward travel, One Step swtch ON, scrub mode swtch n scrub only or scrub & vacuum poston VDC VDC VDC VDC VDC VDC RED BLK MACHINE CONTROLLER RED KEYSWITCH FU-5 0 A SIGNAL OUTPUT FU- 5 A PIN P-8 PIN P- + POS NEG - PIN P- Used for conventonal scrubbng ONLY 9 FU- 0 A *PWM* BLK VDC Wth Key ON BDI STATIC DRAIN (Connected to metal frame of machne) SWITCHED GROUND PIN P-9 PIN P-8 PIN P-9 PIN P- PIN P-5 5VDC REFERENCE SIGNAL INPUT SOLUTION VALVE VDC Wth Key ON Wrng Color Codes (Unless otherwse marked) Rght Most Dgt of Wre Number Color of Wre Tan Pnk Brown Orange Yellow Green Blue Purple Gray Whte 0VDC REFERENCE Used for conventonal scrubbng ONLY SOLUTION FLOW CONTROL POTENTIOMETER t all machnes use electronc Soluton Flow Control some machnes use a mechancal devce to control the amount of soluton appled to the floor If electronc Soluton Flow Control s used, the Soluton Valve s controlled by Pulse Wdth Modulaton The Soluton Valve and Soluton Flow Control Potentometer s used only durng conventonal scrubbng they are NOT used durng FaST scrubbng Typcal Soluton Valve current draw: 0. to 0.5 Amps

48 EZ Rder HP Fuses & Crcut Breaker fuse # ratng crcut protected locaton Machne On Machne Controller where FU- 5 Amps Controller Battery (+) cable attaches FU- FU- FU- FU-5 0 Amps 0 Amps 0 Amps 0 Amps Fuses Soluton Valve; ES Pump; Recovery Tank Full Lamp; Back-up Alarm Squeegee Lft Actuator Scrub Head Actuator Key Swtch; BDI; Machne Controller Near the two mult-pn connectors on the Machne Controller crcut breaker # ratng crcut protected locaton CB- 0 Amps Crcut Breaker FaST Detergent, Ar, & Water Pumps; FaST Solenod Valve; FaST Tmer Module On the lower part of the operator console

49 Troubleshootng Gude for the PG Drves Tro Controller Ths gude was prepared to help you dagnose and repar the machne controller. It s recommended that you begn your troubleshootng at the START pont on page. The followng chart lsts the contents of ths troubleshootng gude page descrpton START pont for troubleshootng TEST : Scrubbng Functons Troubleshootng Covers the followng functons: 5 Scrub brush motors, scrub head and squeegee actuators, and vacuum fan TEST : Other Systems Troubleshootng Covers the followng functons: 8 ES system, recovery tank full lght, horn, & soluton flow control (f electrcally controlled) 9 TEST : Propellng Troubleshootng 0 Covers tracton motor and foot throttle TRIO pn confguratons dagram TRIO connectors P & P pn nputs and outputs charts TRIO battery cable connectons dagram - 5 TRIO BDI charts & dagrams Page of 5 5

50 Safety & Test Requrements: Dsconnect tracton motor plug on Tro Drve wheel off ground, back wheels blocked Key swtch on & unplug seat swtch TRIO Controller tes Controller wll be referred to as TRIO BDI s Battery Dscharge Indcator! Dsconnect tracton motor plug from Tro before conductng these tests! te: Refer to dagram on page Controller System Troubleshootng START Wth key on, do any BDI segments lght up? te: For nformaton on the Tro pn confguratons, go to pages & te: Refer to Page, Fgure Be sure to have adequate battery charge What system s not workng properly? Steady or flashng segments Propel system Go to TEST Page 9 What s BDI status? Segments rpplng up and down Wth meter leads on the Tro s battery cable bolts, s battery voltage measured? Wth key on or off, s there battery voltage at Tro connector P pn# 8? te: Refer to Page, Fgure Scrubbng system Go to TEST Page Other systems Go to TEST Page te: Refer to dagram on page Wth key off, s there contnuty between BDI pn# & Tro connector P pn# 9? Wth key on, s there battery voltage at BDI pn#? Reset or replace emergency stop swtch, check all fuses, check all wrng connectons, recheck fuses & wrng, replace Tro f needed Wth meter leads on the battery cable ends at the Tro, s battery voltage measured? Replace man fuse on Tro at B+ connecton Replace BDI Wth key off, s there contnuty between BDI pn# & Tro connector P pn#? Verfy problem s repared - retest from START Repar/replace wre or connectons Check/replace Fuse# 5 (0 amps), check/replace gnton swtch Verfy problem s repared - retest from START Verfy problem s repared - retest from START Repar or replace battery cables, charge or replace batteres Page of 5

51 Safety & Test Requrements: Dsconnect tracton motor plug on Tro Throttle pedal depressed (forward) Recovery tank level below float swtches Drve wheel off ground, back wheels blocked Unplug seat swtch Key & Scrub swtch on TEST Scrub System Scrubbng System Troubleshootng! Dsconnect tracton motor plug from Tro before conductng these tests! te: Ths test wll cover scrub brush motors, scrub head and squeegee actuators, and vacuum fan Does ether brush motor operate? Scrub brush motors te: Scrub Mode Swtch must be n Scrub Only or Scrub/Vac poston What system s not workng properly? Scrub head actuator Squeegee actuator Vacuum fan te: Scrub Mode Swtch must be n Vac Only or Scrub/Vac poston Repar/replace wre or connectons, repar/replace non-workng motor(s) Verfy problem s repared - retest from START Remove Brush connector from Tro s there battery voltage at Brush(+) and Brush(-) on Tro? te: Refer to Tro pn confguratons, pages & Is there battery voltage at Tro P pns &, and does t swtch polarty when scrub swtch s toggled on & off? Go to C Page 5 Repar/replace float swtch, wrng, or connectors Unplug recovery tank Full float swtch s there battery voltage at Brush(+) and Brush(-) on Tro? Repar/replace Fuse, repar/replace wrng & connectons, repar/replace scrub head actuator Go to A Page Verfy problem s repared - retest from START Go to B Page Page of 5 Go to D Page 5

52 Scrubbng System Troubleshootng Safety & Test Requrements: Dsconnect tracton motor plug on Tro Throttle pedal depressed (forward) Recovery tank level below float swtches Drve wheel off ground, back wheels blocked Unplug seat swtch Key & Scrub swtch on A (Contnued from page ) B (Contnued from page ) te: Refer to Tro pn confguratons, pages & Wth voltmeter leads on Tro P pn and P pn 9, s there.5 to 5 volts? (polarty unmportant) Wth meter leads on Tro P pn and P pn 5, s there.5 to 5 volts? (polarty unmportant) Wth key off, scrub mode swtch n Scrub Only, brush pressure swtch Heavy - s there contnuty between ALL Tro P Pns,,, & 9? Check all fuses, check all wrng & connectons, recheck fuses & wrng, replace Tro f needed Repar/replace wrng from actuator to Tro P pns 5,, or, repar/ replace actuator, recheck all wrng & connectors, replace Tro f needed Wth key off, scrub mode swtch n Scrub & Vac, brush pressure swtch rmal - s there contnuty between ALL Tro P Pns,,, &? Repar/replace faulty swtches or repar/replace wrng & connectons Verfy problem s repared - retest from START Check all Tro wrng & connectons, replace Tro f needed Check all fuses, check all wrng & connectons, recheck fuses & wrng, replace Tro f needed Verfy problem s repared - retest from START Page of 5 8

53 Safety & Test Requrements: Dsconnect tracton motor plug on Tro Drve wheel off ground, back wheels blocked Throttle pedal depressed (forward) Unplug seat swtch Recovery tank level below float swtches Key & Scrub swtch on C (Contnued from page ) te: Refer to Tro pn confguratons, pages & Is there battery voltage at Tro P pns & 0? Unplug recovery tank Full float swtch does actuator functon? Repar/replace Fuse #, repar/replace wrng & connectons, repar/replace squeegee actuator Verfy problem s repared - retest from START Repar/replace float swtch, wrng, or connectors Go to A Page Scrubbng System Troubleshootng D (Contnued from page ) Is there battery voltage at Tro Vacuum(+) and Vacuum(-)? Repar/replace vacuum fan or wrng and connectors Unplug recovery tank Full float swtch does actuator functon? Verfy problem s repared - retest from START Repar/replace float swtch, wrng, or connectors Go to A Page Page 5 of 5 9

54 Safety & Test Requrements: Dsconnect tracton motor plug on Tro Throttle pedal depressed (forward) Recovery tank level below float swtches Drve wheel off ground, back wheels blocked Unplug seat swtch Key & Scrub swtch on TEST Other Systems Other Systems Troubleshootng! Dsconnect tracton motor plug from Tro before conductng these tests! te: Ths test wll cover the ES system, recovery tank full lght, horn, & soluton flow control (f electrcally controlled) te: Refer to Tro pn confguratons, pages & te: To test ES system, have / to / full recovery tank & ES swtch on ES system What system s not workng properly? Recovery tank full lght te: To test soluton control system, have an empty recovery tank & soluton tank flled Soluton flow control Wth voltmeter on Tro P pns &, s there battery voltage? Check Fuse #, repar/replace ES pump, wrng or connectors Verfy problem s repared - retest from START Check all fuses, check all wrng connectons, recheck fuses & wrng, replace Tro f needed Wth key off, s there contnuty between ALL Tro P pns 5 & and? Repar/replace recovery tank half full swtch, repar/replace ES swtch, repar/replace wrng & connectors Move tank full swtch float up & down does lght go on & off? Verfy problem s repared - retest from START Clean or repar/replace recovery tank full float swtch Horn te: Refer to Tro pn confguratons, pages & Wth key off, s there contnuty between Tro P pn & P pn? Go to E Page Go to F Page Go to G Page 8 Check Fuse #, repar/replace recovery tank full lght, repar/ replace wrng & connectors Verfy problem s repared - retest from START Page of 5 50

55 Other Systems Troubleshootng Safety & Test Requrements: Dsconnect tracton motor plug on Tro Throttle pedal depressed (forward) Recovery tank level below float swtches Drve wheel off ground, back wheels blocked Unplug seat swtch Key & Scrub swtch on E (Contnued from page ) Wth key off, s there contnuty between Tro P pn 5 & P pn? Repar/replace horn swtch or horn F (Contnued from page ) Wth key on & voltmeter on wres at horn swtch, s there battery voltage? Check all fuses, check all wrng connectons, recheck fuses & wrng, replace Tro f needed Verfy problem s repared - retest from START Wth key off, s there contnuty between horn swtch wre 0/Tan and Tro Battery(-)? Repar/replace recovery tank full swtch, repar/replace wrng & connectors, replace Tro f needed Repar/replace horn swtch or horn, repar/replace wrng & connectors from Tro P pn 8 to horn swtch. Repar/replace horn, repar/replace wrng & connectors from Tro Battery(-) to horn. Verfy problem s repared - retest from START Verfy problem s repared - retest from START Page of 5 5

56 Other Systems Troubleshootng Safety & Test Requrements: Dsconnect tracton motor plug on Tro Throttle pedal depressed (forward) Recovery tank level below float swtches Drve wheel off ground, back wheels blocked Unplug seat swtch Key & Scrub swtch on G (Contnued from page ) Repar/replace Fuse #, repar/replace soluton valve, repar/replace wrng & connectors Wth key off, s there contnuty between Tro P pn & 9? Verfy problem s repared - retest from START Verfy proper operatng soluton valve, check all fuses, check all wrng connectons, recheck fuses & wrng, replace Tro f needed Wth key on, does the voltage at Tro P pns & 9 vary steadly from 0 to 5 volts as soluton flow control potentometer s slowly turned from low to hgh flow? (polarty unmportant) Check voltage at potentometer on wres P/Green & A/Purple s t approx.5 to 5 volts? (polarty unmportant) Dsconnect plug at soluton flow control potentometer measure resstance between whte & orange wres of potentometer s t approx 5k ohms? Repar/replace soluton flow control potentometer Verfy problem s repared - retest from START Verfy proper operatng soluton flow control potentometer, check all fuses, check all wrng connectons, recheck fuses & wrng, replace Tro f needed Repar/replace wres from P pn or pn 9 to potentometer, check all fuses and wrng & connectons, replace Tro f needed Verfy problem s repared - retest from START Verfy problem s repared - retest from START Page 8 of 5 5

57 Safety & Test Requrements: Dsconnect tracton motor plug on Tro Key swtch on Drve wheel off ground, back wheels blocked Unplug seat swtch TEST Propel System Propellng Troubleshootng te: Ths test wll cover the tracton motor & foot throttle Repar/replace seat swtch, repar/replace wrng and connectors, replace Tro f needed Does machne propel wth seat swtch unplugged and tracton plug plugged nto Tro?! Verfy problem s repared - retest from START Dsconnect tracton motor plug from Tro before conductng ths test! te: Refer to Tro pn confguratons, pages & Measure NEUTRAL voltage at Tro P pns 9 & 0 - Is t approx..5 to.5 volts? (polarty not mportant) Is BDI rpplng up and down? Go to H Page 0 Wth leads stll connected, press throttle pedal slowly to full forward, then slowly to full reverse Is there a steady rse/fall from Neutral voltage to 0 volts n one drecton, and to approx. 5 volts n the other drecton? (polarty not mportant) Wth key off, unhook connector P measure resstance on connector plug wres on pns 9 & 0 s t approx. 0k ohms? Go to H Page 0 Adjust or repar/replace throttle potentometer Verfy problem s repared - retest from START Replace throttle potentometer. Wth P connected & key on, check/adjust potentometer to get.5 to.5 volts at Tro P pns 9 & 0 Page 9 of 5 5

58 Safety & Test Requrements: Dsconnect tracton motor plug on Tro Drve wheel off ground, back wheels blocked Propellng Troubleshootng Key swtch on Unplug seat swtch te: Refer to Tro pn confguratons, pages & H (Contnued from page 9) At tracton connecton on Tro (connector unplugged), s there a steady rse to near battery voltage when throttle s pressed slowly to full forward, and approx. 0 volts full reverse? (polarty unmportant) Repar/replace tracton motor, wrng, or connectors Verfy problem s repared - retest from START Check all fuses, check all wrng & connectons, recheck fuses & wrng, replace Tro f needed Page 0 of 5 5

59 Tro Pn Confguratons NOTE: As vewed from rear of connectors (wre sde) 5 5 Page of 5 55

60 Connector P pn nput/output descrpton P- OUTPUT SWITCHED BATTERY (+) FROM KEY SWITCH P- OUTPUT ES PUMP [BATTERY (-)] P- OUTPUT SQUEEGEE ACTUATOR [BATTERY (+) OR (-)] P- OUTPUT SCRUB HEAD ACTUATOR [BATTERY (+) OR (-)] P-5 OUTPUT 0 VDC REFERENCE P- INPUT SCRUB HEAD ACTUATOR RETRACT P- INPUT ES SWITCH P-8 X NOT USED P-9 OUTPUT SOLUTION VALVE [BATTERY (-)] P-0 OUTPUT SQUEEGEE ACTUATOR [BATTERY (+) OR (-)] P- OUTPUT SCRUB HEAD ACTUATOR [BATTERY (+) OR (-)] P- X NOT USED P- INPUT RECOVERY TANK HALF FULL SWITCH P- INPUT SCRUB HEAD ACTUATOR EXTEND Tro Pn Inputs & Outputs Connector P pn nput/output descrpton *P- INPUT SOLUTION FLOW CONTROL (0 TO 5 VDC) P- INPUT SCRUB HEAD TYPE (TRI-STATE) P- INPUT SCRUB ON/OFF & BRUSH PRESSURE P- INPUT EMERGENCY STOP SWITCH **P-5 INPUT SOLUTION FLOW CONTROL (0 TO 5 VDC) P- OUTPUT BATTERY DISCHARGE INDICATOR P- OUTPUT RECOVERY TANK FULL LAMP [BATTERY (-)] P-8 OUTPUT CONSTANT BATTERY (+) P-9 OUTPUT 0 VDC REFERENCE P-0 INPUT THROTTLE POSITION (0 TO 5 VDC) P- INPUT SCRUB MODE SWITCH (TRI-STATE) P- INPUT SCRUB ON/OFF & BRUSH PRESSURE P- X NOT USED P- INPUT RECOVERY TANK FULL SWITCH P-5 INPUT SEAT SWITCH P- OUTPUT 5 VDC REFERENCE P- OUTPUT BACK-UP ALARM [BATTERY (-)] P-8 INPUT SWITCHED BATTERY (+) FROM KEY SWITCH P-9 OUTPUT 0 VDC REFERENCE P-0 OUTPUT 5 VDC REFERENCE * P- not used on machnes wth seral numbers 00 and above ** P-5 not used on machnes wth seral numbers to 00 Page of 5 5

61 Ths wll check for battery voltage to the Tro Multmeter volts?? V FIGURE Bolt Washer Shoulder Washer Fuse Insulator Multmeter volts?? V FIGURE Bolt Negatve Battery Cable Ths wll check for a blown fuse. If battery voltage s measured on the Tro s battery cable hold-down bolts, fuse s OK. Tro Battery Cable Connectons Tro Controller Postve Battery Cable Page of 5 5

62 BDI Status Indcators Tro BDI Informaton Indcator Descrpton Red, yellow, and green LED's lt (not flashng) System OK, no faults found, adequate charge n batteres Only red and yellow LED's lt (not flashng) Batteres wll soon need to be charged Only red LED's lt (not flashng) Charge batteres mmedately LED's rpple up only (not down) Batteres are beng charged BDI blnks on every 5 seconds Controller has entered sleep mode after 0 mnutes of nactvty BDI flashng rapdly Fault has been sensed; Refer to BDI Dagnostc Codes below Rpple Up & Down Throttle pedal depressed at start-up BDI top vew BDI sde vew wth cable & plug y NOTE: As vewed from rear of connector (wre sde) BDI Dagnostc Codes # Bars Flashng Descrpton of Fault Possble Causes LOW BATTERY VOLTAGE Batteres need charged; Bad connecton to batteres TRACTION MOTOR FAULT Bad connecton to propel motor SCRUB BRUSH MOTOR FAULT Bad connecton to scrub brush motors NOT USED 5 VACUUM MOTOR FAULT Bad connecton to vacuum fan motor SEAT SWITCH FAULT Operator not on seat; Faulty seat swtch THROTTLE FAULT Throttle depressed before start-up 8 CONTROL SYSTEM FAULT Emergency Stop Swtch actvated; Wrng ssue; Faulty Tro controller 9 NOT USED 0 EXCESSIVE BATTERY VOLTAGE Bad connecton to batteres NOTE: Rpple Up & Down ndcates throttle pedal depressed at start-up Page of 5 58

63 Tro BDI Informaton for Models wth Optonal On-board Charger BDI Status Indcators Indcator Descrpton Red, yellow, and green LED's lt (not flashng) System OK, no faults found, adequate charge n batteres Only red and yellow LED's lt (not flashng) Batteres wll soon need to be charged Only red LED's lt (not flashng) Charge batteres mmedately LED's rpple up only (not down) Batteres are beng charged BDI blnks on every 5 seconds Controller has entered sleep mode after 0 mnutes of nactvty BDI flashng rapdly Fault has been sensed; Refer to BDI Dagnostc Codes below Rpple Up & Down Throttle pedal depressed at start-up BDI sde vew wth cable & plug BDI top vew # Bars Flashng # of Flashes Descrpton of Fault Possble Causes LOW BATTERY VOLTAGE Batteres need charged; Bad connecton to batteres TRACTION MOTOR FAULT Bad connecton to propel motor SCRUB BRUSH MOTOR FAULT Bad connecton to scrub brush motors SCRUB HEAD ACTUATOR FAULT Faulty actuator; Actuator unplugged SQUEEGEE ACTUATOR FAULT Faulty actuator; Actuator unplugged 5 VACUUM MOTOR FAULT Bad connecton to vacuum fan motor SEAT SWITCH FAULT Operator not on seat; Faulty seat swtch y NOTE: As vewed from rear of connector (wre sde) THROTTLE FAULT Throttle depressed before start-up INPUT SWITCH FAULT Incorrect throttle pedal sgnal; Open throttle potentometer 8 CONTROL SYSTEM FAULT Emergency Stop Swtch actvated; Wrng ssue; Faulty Tro controller 9 BDI Dagnostc Codes RECOVERY TANK FULL FAULT Faulty level sensor; ; Level sensor unplugged BACK-UP ALARM FAULT Faulty back-up alarm; Shorted back-up alarm or faulty wrng SOLUTION VALVE FAULT Incorrect soluton valve sgnal; Open soluton valve potentometer ES PUMP FAULT Faulty ES pump; Shorted ES pump or faulty wrng 5 HOUR METER FAULT Faulty hour meter; Shorted hour meter or faulty wrng 0 EXCESSIVE BATTERY VOLTAGE Bad connecton to batteres NOTE: Rpple Up & Down ndcates throttle pedal depressed at start-up Page 5 of 5 59

64 FaST Overall System Troubleshootng FaST Operatonal Requrements: Adequate battery charge START WARNING! Unplug electrcal connectors to propel motor and scrub brush motors before servcng! Water tank suffcently full FaST-Pak suffcently full & connected Ignton swtch on FaST/conventonal swtch set to FaST Scrub head lowered & brushes engaged Verfy FaST operatonal requrements; Remove hose at Test Pont L, (Refer to CHART # ), engage forward propel Is any foam or lqud beng dscharged? Forward propel engaged - be sure to read warnng at START NOTE: If customer s complanng of too much detergent usage, check pulse rate per mnute of detergent pump (Refer to CHART # ) If not wthn specfcatons, go to TEST # Check soluton flow per mnute: To check output by weght, drect foam or lqud dscharge nto contaner and wegh on scale (Refer to CHART # for soluton flow weght per mnute) To check output by volume, drect foam or lqud dscharge nto contaner, allow tme for foam to collapse nto a lqud state, and measure lqud volume (Refer to CHART # for soluton flow volume per mnute) LESS than specfcatons What s the soluton flow output per mnute? MORE than specfcatons OK per specfcatons NOTE: For excess foamng ssues, verfy that only FaST detergent s beng used and/or the water tank has been draned and rnsed before FaST scrubbng Is water pump operatng? Go to TEST # Is ar pump operatng? Go to TEST # Go to TEST # Go to TEST # Go to TEST # Go to TEST # 5 Page of 8 0

65 FaST Troubleshootng - TEST # (Low/no water or foam) FaST Operatonal Requrements: Adequate battery charge Water tank suffcently full FaST-Pak suffcently full & connected Ignton swtch on FaST/conventonal swtch set to FaST Scrub head lowered & brushes engaged Forward propel engaged - be sure to read warnng at START TEST # WARNING! Unplug electrcal connectors to propel motor and scrub brush motors before servcng! Remove hose at Test Pont G (Refer to CHART # ), check water flow per mnute (after orfce): - To check output by weght, drect lqud dscharge nto contaner and wegh on scale (Refer to CHART # for water flow weght per mnute) - To check output by volume, drect lqud dscharge nto contaner and measure lqud volume (Refer to CHART # for water flow volume per mnute) LESS than specfcatons What s the water flow output per mnute? NOTE: The orfce s a thn round metal dsc wth a very small hole n the center. Use ONLY brass or softer materal to clean hole n orfce Remove hose at Test Pont D- Is flow rate OK per specfcatons lsted n CHART # (after orfce)? MORE than specfcatons OK per specfcatons Check for blockage n hoses from flter/orfce to Test Pont G; verfy operaton & orentaton of check valve; verfy battery voltage at FaST solenod valve; check for restrcton n FaST solenod valve; repar system as needed Verfy problem s repared - rerun test from START - If OK, reconnect propel & brush motors DONE NOTE: Arrow on check valve (f used) should pont away from water pump Check for blockage at flter/orfce, or hoses from water pump to orfce assembly; repar system as needed Remove hose at Test Pont C- Is flow rate OK per specfcatons lsted n CHART # (before orfce)? Check for blockage n hoses from water tank to water pump, check 80 mesh flter for blockage - Is flow rate at Test Pont C OK per specfcatons lsted n CHART # (before orfce)? Go to TEST # Go to TEST # Check system from Test Pont G to scrub head - Check for blockage n hoses or mxng chamber; repar system as needed Verfy problem s repared - rerun test from START - If OK, reconnect propel & brush motors DONE Page of 8

66 FaST FaST Operatonal Requrements: Adequate battery charge Water tank suffcently full Troubleshootng - TEST # NOTE: The orfce s a thn round metal dsc wth a very small hole n the center. Use ONLY brass or softer materal to clean hole n orfce TEST # (Too much water and low/no foam) WARNING! Unplug electrcal connectors to propel motor and scrub brush motors before servcng! FaST-Pak suffcently full & connected Ignton swtch on FaST/conventonal swtch set to FaST Dsassemble flter/orfce near Test Pont D (Refer to CHART # ) - Is orfce clean & n place? Scrub head lowered & brushes engaged Forward propel engaged - be sure to read warnng at START Remove wres from conventonal system solenod valve & check output at Test Pont L - Is foam now beng dscharged? Clean or nstall new orfce Verfy problem s repared - rerun test from START - If OK, reconnect propel & brush motors NOTE: The correct order for assembly of flter/orfce s (n drecton of water flow): flter, washer, orfce. Inspect wrng at FaST/ Conventonal Swtch; test swtch; repar wrng or replace FaST/Conventonal swtch Remove hose from output sde of conventonal system solenod valve to verfy leakage; replace conventonal system solenod valve DONE Verfy problem s repared - rerun test from START - If OK, reconnect propel & brush motors Verfy problem s repared - rerun test from START - If OK, reconnect propel & brush motors DONE DONE Page of 8

67 FaST FaST Operatonal Requrements: Adequate battery charge Troubleshootng - TEST # WARNING! Unplug electrcal connectors to propel motor and scrub brush motors before servcng! (Water OK, no foam) TEST # Water tank suffcently full FaST-Pak suffcently full & connected Ignton swtch on FaST/conventonal swtch set to FaST Scrub head lowered & brushes engaged Forward propel engaged - be sure to read warnng at START NOTE: Ar pump measurements: Inlet - Approx. 0 to 5 nches Hg (5 to.5 cm Hg) Outlet - Approx. 0 to 0 PSI (8 to 0 kpa) Remove hose at Test Pont F (Refer to CHART # ), check detergent flow per mnute: To check output, drect lqud dscharge nto contaner and measure lqud volume (Refer to CHART # for detergent flow volume per mnute) Is detergent flow rate OK per specfcatons lsted n CHART #? Is ar pump workng properly as per specfcatons? Check for blockage n hoses from FaST detergent pack to Test Pont F; repar or replace tems as needed Clean or replace mxng chamber Verfy problem s repared - rerun test from START - If OK, reconnect propel & brush motors DONE Inspect flow through mxng chamber Is mxng chamber clogged wth debrs? NOTE: Arrow on check valve should pont away from ar pump Check for blockage from Test Ponts I to G, check for proper orentaton & operaton of check valve, repar or replace tems as needed Go to TEST # Verfy problem s repared - rerun test from START - If OK, reconnect propel & brush motors DONE Is detergent flow rate OK per specfcatons lsted n CHART #? Go to TEST # Page of 8

68 FaST Troubleshootng - TEST # (Indvdual component testng) FaST Operatonal Requrements: Adequate battery charge Water tank suffcently full TEST # WARNING! Unplug electrcal connectors to propel motor and scrub brush motors before servcng! FaST-Pak suffcently full & connected Ignton swtch on FaST/conventonal swtch set to FaST Scrub head lowered & brushes engaged Forward propel engaged - be sure to read warnng at START Do components have the correct nput voltage readngs as lsted below? Repar or replace faulty component Verfy problem s repared - rerun test from START - If OK, reconnect propel & brush motors DONE rmal operatng voltages at FaST components Water pump De te rge nt pump Ar pump Solenod valve Tmer module vdc systems vdc systems Battery voltage Pulsed battery voltage (Refer to CHART # for pulse rate) Batte ry voltage to 8 vdc Battery voltage Constant battery voltage at posts & ; Pulsed battery voltage at posts & (Refer to CHART # for pulse rate) Go to TEST # 5 ohm t used resstor 8 to vdc Voltage drop across resstor Page 5 of 8

69 FaST FaST Operatonal Requrements: Troubleshootng - TEST #5 Check wrng n FaST harness for short crcut or loose connectons repar or replace as needed rmal operatng amperages of FaST components Water pump De te rge nt pump Ar pump Sole nod valve Tmer module ohm resstor System Total Adequate battery charge Water tank suffcently full FaST-Pak suffcently full & connected Ignton swtch on FaST/conventonal swtch set to FaST Scrub head lowered & brushes engaged Forward propel engaged - be sure to read warnng at START Approx..8 to.5 Amps Approx. 50 to 50 ma Approx. 00 to 00 ma Approx. 00 to 00 ma Approx. 5 to 5 ma Approx. 00 to 50 ma (f used) Approx..5 to.0 Amps WARNING! Unplug electrcal connectors to propel motor and scrub brush motors before servcng! Reset crcut breaker Usng the amperage chart, check current draw of FaST components Do components test OK? Repar or replace components as needed Verfy problem s repared - rerun test from START - If OK, reconnect propel & brush motors DONE TEST # 5 Is FaST crcut breaker trpped? Replace FaST/ Conventonal swtch Verfy problem s repared - rerun test from START - If OK, reconnect propel & brush motors (Overall electrcal testng) Does conventonal system work properly? Connect jumper wre on FaST swtch from center post to outer post (leadng to FaST relay) Does FaST system work? Replace FaST relay or repar wrng to relay Verfy problem s repared - rerun test from START - If OK, reconnect propel & brush motors DONE Connect jumper wre on FaST swtch from center post to outer post (leadng to conventonal solenod valve) Does conventonal system work? Be sure to follow FaST operatonal requrements f OK, then repar electrcal system before FaST system Page of 8 5

70 FaST Test Ponts - CHART # A B C D E Water Tank 80 Mesh Flter Water Pump Flter/ Orfce Check Valve Conventonal Soluton System NOTE: Hose path vares by model Conventonal Solenod Shut Off Valve L FaST-Pak Detergent Quck Dsconnect w/check valves K J Detergent Pump (Pulsed by Tmer) Ar Compressor Check Valve I H Solenod Shut Off Valve ** F G Scrub Head Mxng Chamber NOTES Flow Drecton arrow Item n dotted lne not used on all models ** Solenod locaton vares by model number (may be located before or after the detergent Tee ) Page of 8

71 FaST Specfcatons - CHART # FaST water and detergent flow specfcaton chart Descrpton / Measurement Specfcaton Water Pump part # 0058 Water Pump pressure before orfce (ps) 0-5 (nternally releved) Water pressure after orfce (ps).0 Water Pump head part # 9 Water flow before orfce (L/mn) 5. Water flow before orfce (GPM). Water flow before orfce (kg/mn) 5. Water flow before orfce (lb/mn). Lqud flow after orfce (L/mn). Lqud flow after orfce (GPM) 0. Lqud flow after orfce (kg/mn). Lqud flow after orfce (lb/mn).5 Orfce & body part # 05 Orfce plate part # 00 Orfce dameter (nches) 0.05 Detergent pump pulse rate per mn. Detergent flow (ml/mn).5 Page 8 of 8

72 Optonal On-board Charger Setup Instructons Page of DESCRIPTION: The charger s set at the factory to match the batteres suppled wth your machne. These nstructons explan how to change the charger settngs f the charger s purchased as an aftermarket part or f the charger settngs need to be changed for dfferent type or sze of batteres. Please follow step-by-step nstructons. SPECIAL TOOLS / CONSIDERATIONS: NONE (Estmated tme to complete: 5 mnutes) PREPARATION: Ths charger has nne settngs for varous types of batteres. Always make sure the charger s at the proper settng BEFORE chargng batteres. The green ndcator lght flashes (when the charger s frst plugged nto an AC outlet) to show the charger settng. DO NOT plug the charger nto a battery at ths pont. Count the number of flashes separated by a pause to determne the charger settng (.e.,three flashes, pause, three flashes, pause, etc. means the charger s n the thrd settng). Refer to Fg.. Tennant uses only two of the charger settngs;. Settng ( flashes) s for VDC systems wth battery ratngs between Ah.. Settng ( flashes) s for VDC systems wth battery ratngs more than 50Ah. NOTE: If chargng batteres not suppled by Tennant, use the charger manufacturer s nstructons to determne whch settng to use.. Read the nstructons provded by the charger manufacturer and the nstructons and safety messages (Refer to Fg. ) mounted on the charger for nstallaton/operaton nstructons and safety nformaton. Fg. Fg. 8

73 Optonal On-board Charger Setup Instructons Page of TO CHANGE CHARGER SETTING:. Plug the charger nto the an AC outlet. The charger wll run through a self test for about seconds. Then the green ndcator lght wll flash for seconds to show the charger s current settng. (See prevous page). The charger settng must be changed durng ths second tme span. NOTE: If you wated more than seconds to change the settng, the red ndcator lght wll turn on. When ths happens, unplug the charger from the AC outlet, wat a few seconds, then replug t nto the outlet to start the cycle over.. Durng the second tme span, connect the charger to the battery connector for seconds, and then unplug the charger from the battery (Refer to Fg. ). The charger wll advance to the next settng.. Repeat prevous step untl the desred settng s dsplayed.. After the desred settng s reached, plug the charger connector nto the battery connector untl the output relay clcks (ths happens 0 seconds after t s plugged n). The ndcator lght wll flash red and the settng s saved n the charger memory. NOTE: To change to a settng for another sze battery, unplug the charger from the AC outlet, wat a few seconds, then replug the charger back nto the AC outlet. Follow Steps through to change the settng. 5. The charger can now be used to charge batteres. (See Machne Operaton manuals for chargng nstructons). Fg. TENNANT COMPANY P. O. Box 5 Mnneapols, MN