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Advance SC750 and SC800 Service Manual

1. 001 RED 10 2 BLK 10 X46 45 X41 lil X40 24 VDC E i X10 RED BLK ON BOARD BATTERY CHARGER OPTIONAL gt S P E MODEL HF2 U124V25A 1 INTERLUCK IN INTERLOCK SERIAL COMM Ady 8 M3 See Me X36 LT BRUSI ya 005 ORN 10 O zs X19 554 X20 33 Ay A bos X43 X42 F1 008 RED 10 unl Mog SW SPST KEY 009 WHT BRN 18 ii soon ball X1
2. S7 S8 59 Eu 001 RED 10 5 58 5 d 5 002 BLK 10 5 EE LE X106 RED BLK X46 x45 003 WELDING RED 1 lil X40 004 WELDING BLK BATTERY CHARGER OPTIONAL gt 1 a4 VDC adi S P E MODEL HF2 U124V25A INTERLOCK IN INTER OCK SERIAL COMM M3 A 558 LT BRUSH 55 CB1 005 ORN 10 A we X36 X39 22 30 AMP m 9 l X43 X42 ang peng ___ 220 um A 965 we X15 X16 SW SPST KEY 009 WHT BRN xmi x WELDING RED 1 yd CB2 X11 011 WHT BLU 18 e X38 00 014 RED 16 X17 yE 18 X5
3. X47 10 AMP X18 17 016 YEL 18 X51 1 X9 2 017 BRN 18 020 YEL 18 2 1 X72 YE 5 io SUE 023 BRN 18 SWITCHES 3 2 8 S4 R2 gt 29 s 30 SPEED LIMIT POT 100K OHM e 52 X28 X64 J1 4 8 9 10 X25 X26 5 5 3 3 3 X50 CHASSIS BONDING 1 OPERATOR INTERFAC 8 CONNECTION X50 X8 x7 7 85 86 X24 T 5 8 T 5 2 x23 _ 5 i23 8 p z 8 30 87 g PINK X21 S 069 BRN 18 55 REVERSE SW 5 75 09 cb ob ob 0 m E HOUR METER 2 lt x g OP TIONAL X34 BLK B SSGSSS BLK b P pn m 18 012 WELDING BLK 1 061 BLK 18 072 BLK LL 9 UE 070 WELDING BLK 6 052 BLK 10 076 BLK 12 076 BLK 12 112 SP1 CHASSIS BONDING ELECTRICAL PANEL 5 053 GRN YEL 16 if Form Number 56043150 Page 74 service Manual 5 750 SC800 SC 750 ST 50800 ST VACUUM o SW 59 m Page 2 of 3 SOLUTION SW 009 WHT BR Pi EG NO CONNECTION 010 BRN 18 002 BLK 10 12052456 12052456 ON BC BATTERY Ct 5 MODEL H s B INTERLOCK 1N INTEREOCt GRA GRA YEL
4. BLK BLK BRN J4 5 KEY SW IN 243 auxe gt BLK 84 10 status OUT PG DRIVES SPEED CONTROLLER _ MODE ic 4 70 S471 GRA CRA J4 13 0 vni vs PINK PINK _J4 12 RkEV SWITCH IN SW REVERSE 29 WHT 25 2 2 auxi DUT SW TRACTION lt oe BLU 2 BLU 4 1 THROTTLE WIPER C SW TRACTION MOTOR WHEEL DRIVE _ n BLK lt WHT J4 2 HIGH REF POT SPD LMT BER BEN ___ __ J4 9 SPEED LIMIT WIPER WHT lt 24 8 THROTTLE LOW REF RES R4 4 75K BLK BLK 4 AL gt BRN i A4 BLK HLIUR METER 3 4 WHT NC Form Number 56043150 Page 67 service Manual 5 750 SC800 SC 750 ST 5 800 ST Wiring Harness Configuration Diagram 56112171 REV D SC750 and SC800 The first page is a complete view When viewing on a computer it can be enlarged to be legible while retaining the convenience of a single page The following pages are the same diagram enlarged on multiple pages so that they are legible when printed There is overlap across the pages When printed they can be lined up and taped together
5. winvacom motor ruming so NN 12 Connector Circuit Description Battery Negative Ground With vacuum motor running 2 Battery Negative Ground With vacuum motor running 3 Input from Brush Deck actuator position switch 4 95V Up Position Other positions 0 5 Both HO Switch floats open when actuator is fully retracted corresponding to a raised deck and is closed to GND otherwise E St Form Number 56043150 Page 51 service Manual 5 750 SC800 SC 750 ST SC800 ST Circuit Description Vacuum Motor Current Sense input voltage on this wire represents the motor current Battery Negative Ground With vacuum motor running Value Comments 181 mV Vacuum motor running with solu tion cover open Dropped to 157 mV when ball float was seated 10 Brush Motor Current Sense input voltage on 30mV Brushes free running not contacting Both this wire represents the motor current floor Input from Brush Deck actuator position switch H1 Switch floats open when actuator is par tially extended corresponding to normal scrub pressure and is closed to GND otherwise 12 Pin has 2 functions 1 Input from Brush Deck actuator position switch 2 Switch floats open when actuator is fully extended corresponding to maximum scrub pressure and is closed to GND other wise 2 When an on board battery charger is in
6. install the sensor onto a new PCB assembly grasp the tube near the end with your fingers and slowly Form Number 56043150 Page 48 service Manual SC750 SC800 SC 750 ST SC800 ST push the tube onto the sensor port Do not push too hard or the sensor may break 12 Reassemble in reverse order noting the following a Take care not to damage the printed circuit ribbons used to connect the circuit board to the control switch interface panel b Reinstall and secure the key switch circuit breakers and handle wiring connector before fastening the cover down If you did not drain the solution tank earlier you must do so before connecting the pressure sensor hose in order for the solution level gauge to work properly d Refer to the wiring connection decal on the back of the cover to reconnect any wires that may have come loose Double check all electrical connections CIRCUIT BREAKER WIRING AS VIEWED FROM BACK OF PANEL YEL 10A 30A YEL X18 1 ORN X20 1 RED X17 1 RED 19 1 KEY SWITCH WIRING AS VIEWED FROM BACK OF SWITCH oF 3 YEL X51 1 MS us X52 1 Form Number 56043150 Page 49 service Manual 5 750 SC800 SC 750 ST 5 800 ST Rocker Switches ST Models 1 Remove the electrical panel cover to access the back side of the rocker switches DO NOT try to access the switches by removing the switch plate as you may damage a ribbon wiring strip 2 Disconnect the ribbon
7. BRN 010 2 vg Ba 019 009 BRN 017 Drive X66 Motor YEL BRN Controller 022 43 14 Main Machine Controller Form Number 56043150 Page 79 service Manual SC750 SC800 SC 750 ST SC800 ST Parking Brake The optional parking brake kit has a manually operated lever that presses a plunger against a drive wheel to act as a brake Laser The laser provides a visual cue of the cleaning path width and provides an early warning that a machine is approaching Laser Line Form Number 56043150 Page 80 service Manual 5 750 SC800 SC 750 ST 50800 ST Recovery System Functional Description The job of the recovery system is to remove the dirty water from the floor and store it in the recovery tank The dirty water is then disposed of Dirt and water are lifted off the floor into the recovery tank by airflow created by a vacuum motor The wastewater and air enter the vacuum system at the squeegee tool through notches in the front squeegee blade The air and wastewater move through the squeegee vacuum hose at high speed until it reaches the recovery tank The heavier water falls to the bottom of the recovery tank The airflow continues through the vacuum fan inlet port vacuum motor and exhaust port A debris tray inside the recovery tanks helps to redirect the water downward and catches large particles No wastewater ever actually moves through the vacuum motor just the working air A floating ball in a
8. 60 Form Number 56043150 Page ii service Manual 5 750 SC800 SC 750 ST SC800 ST Ee eee ee 935 5599 9 9 55 2 55 60 Battery Charger Optional On board Battery Charger L 61 used e OZu Eu xd Ee m d 61 Low Voltage Cut Out Threshold Voltages 61 3 61 Battery Compartment Dimensions 1 6 4 0 0 61 Wiring Diagram 56112170 Rev D Complete Machine 5 750 5 800 62 Wiring Diagram 56112180 REV C Complete Machine 5 750 ST 5 8005 65 Wiring Harness Configuration Diagram 56112171 REV D SC750 and 5 800 68 Wiring Harness Configuration Diagram 56112181 REV SC750 ST SC800 5 73 Options and 77 Battery PH Indicators ec 0e awe eee eee Pekox 4 e 77 Battery Waterme Kite se sa 30 ay doedd 0 3 eR 403 9 eee ead o4 eee TT 6 78 On board battery Charger s gt e s s 4 78 Wiring for On board Charger 2 hea be xw 9 3 wo 9 4 X box w WX 78 Parking Blakes a 4 Ru R4 80 29 3395 x ae ee aes eee 334599
9. o 115 SCUD System uu uw Ede AE We be uR OES ikeen HOES HEH EG 116 Fu unctional Description 666 116 hee eho 116 Functional Circuit Diagram Scrub System REV ig BiG HOHE EEE ox 118 Component Locations Rom i bhi EDU doy 0 deo He nee 119 gt tee 33 x ORO Re Ree ee ee ee 95 120 Scrub Motors Do Not Turn On 6 kad eek eh x wo See o 120 Scrub Deck Will Not Raise or Lower uuu duo we ERE URGE d EE 120 Removal and Installation 4o e oboe re dec ook bo ooo Rer ee Rode 04 5 AD Ro Ow p 122 122 osha eee cee o ae Dee 129 Drive Motor Bearing and Eccentric a uw xw x Xo owoe 4 wd 124 Motor Plate and Isolators s i wa xs eom ook mox dos ea do box mU x A m E e 125 Molor Carbon DHUSDOS rassas e044 6 E xe Eae dur BG WOES d cir 127 Brush Head Actuator sss a susanne tee o d Ro uoa o5 130 SDeCIHCAUIONS S E E ERS 4 E RSG REGRET 26 181 Scrub Motor Amp 18
10. T NL 4 d mo i 969 BRN t8 3 39 X12 poc PY J5 8 AUXI DUT 073 GRA 10 2 2 s X75 8 d Pod h 075 GRN YEL 16 20058 2 X34 5 g 5 x 058 BLK 18 i fub an E Xeg 1 s perius 070 WELDING BLK 6 052 BLK 10 076 BLK 12 076 BLK 12 1 2 025 BLK 12 SP1 062 YEL RED 18 ELECTRICAL PANEL X5 4 68 GRN YEL 16 1 WIRE LENGTH TOLERANCE IS 50 1 00 DO NOT AGCUIMULATETOLERANCES Ay WIRING DIAGRAM SHOWN FOR AQ OPTIONAL WIREING FOR REV2 DECK i COMNECTORE SPECIFIED CONNECTORS SHALL BE USED TERMINALS ANDSEALS DISC BRUSHES LEADS NEED TO BE M3 LEFT MOTOR WHITE TO NEGATIVE BLACK TO POSITIVE 2 CONNECTORS CONNECTORS D ANE REVERSED IN POLARITY UN LEFT BRUSH MOTOR M3 FOR M4 RIGHT MOTOR WHITE TO POSITIVE BLACK TO NEGATIVE IKTENDED FOR WITH THE CONHECTOR M Y USEJ CYLINDRICAL BRUSHES QUE TE TERNA ES HAY BE JSEJ i m a r2 e P 8 _ 4 SLICES ALTERNATE TYPES LICES MAY BE USED AS LORG AS THEY AX WIRING DIAGRAM SHOWN WITHOUT ON BOARD Ss y IMBULATEDARD SEALED CHARGER IF CHARGER IS INSTALLED MAKE 009 WHT BRN 5 COWDUIT ANG SLEEVING ENT BRANDS DE COCHDUIT AND SE EANG MAKE WIRING CHANGES AS NEEDED 022 YEL BRN WAY BE USED 1 MOVE WIRE 022 YEL BRN TD S3 PIN 2 X66 de JE _ E C aeEnm ov
11. TOND ux 137 nea eea 9 3 4 9 WEN 188 Squeegee System 139 Functional Description 189 Component Locations 2 X oV Ae ow ow Xs woo Mood 189 Maintenance and Adjustments x 42 6564 xx EGG EERE RES Ro e HSE ERE ED 140 Adjusting Squeegee ov uuu ee ewe heehee ee be webbed ee Baek 140 Troubleshooting s sers e BAS BEERS OEM REE 44m EE 140 Leaving Streaks on the 140 Removaliand Installation ex ue o E EER OX t u DEES ECS SERS EOE a 140 sw s hae eee eee Bae ee eee a 140 141 Squeegee Blades x ado de m ook woo ow Wood p o ox we XO dox a 141 Wheel System sss ee e ee e 143 Functional Description 143 Component Locations uu we qu ow UE odo eee RO RO OE ee Ee Oe e 148 Wheel System Traction 144 Functional Descriptions 144 Drive Mo
12. Remove a brush and spring Install a new brush and spring into the brush holder Thread the brush wire lead through the brush holder Position the back end of the brush in the cup of the spring so that the spring will unroll as the brush is pushed back once it is installed Push brush back against the spring and insert a stiff temporary retaining wire Paper clip through the access hole in the end cover Remove silicone sealer from the holes The wire must go through the holes in the brush holder just in front of the brush to hold the brush back against the spring pressure 2 M a aper Cli Paper Clip 77 Ss lt gt b N M NA 1 E X P 7 P uM Install the other three brushes Form Number 56043150 Page 128 service Manual 5 750 SC800 SC 750 ST 5 800 ST 6 Install the spring washer so that the fingers will press against the outside bearing race Fingers against Outer Race 7 Install the end cover in stages a Install it far enough so that the brushes will contact the commutator when the temporary retaining wires are removed Then remove the wires Carbon Brush b Fully seat the end cover c Install the through bolts d Sealthe retaining wire holes in the end cover with silicone sealant Form Number 56043150 Page 129 service Manual 5 750 SC800 SC 750 ST 50800 ST Brush Head Actuator 1 Empty recov
13. B 85 86 Switch Relay sense Circuit Voltmeter Main Machine Controller Form Number 56043150 Page 81 service Manual 5 750 SC800 SC 750 ST 5 800 ST The vacuum contactor relay is turned on when the following inputs are met e Operator request o Scrub On Off switch has been pressed Vacuum Wand switch has been pressed e Machine Moving Signal is received from the Drive Motor Controller The vacuum relay is de energized when the operator turns off the scrub system following a timed delay Component Locations Vacuum Motor Cover e Recovery Tank e Recovery Tank Lid e Vacuum Motor e Gasket Recovery Lid e Vacuum Relay Contactor K1 e Recovery Tank Drain Hose e Debris Tray e Squeegee Vacuum Hose e Cage and Ball Float Recovery Tank Drain Hose Recovery Tank Drain F m i cba Hose 4 Vacuum Vacuum Squeegee Motor Cover Vacuum Hose Recovery 4 x Cage and Recovery Ball Float Tank EN Form Number 56043150 Page 82 service Manual 5 750 SC800 SC 750 ST SC800 ST Troubleshooting Vacuum Motor Does Not Turn On Scrub function works Possible Causes e Defective Vacuum Motor e Defective Vacuum Motor Contactor Relay K1 e Defective Wiring e Defective Insufficient Water Pickup Good water pick up performance depends on the proper amount of air flowing through the squeegee pickup tool Air entering the vacuum system before the pickup
14. Static Wheel Pressure center rear 287 6 psi 1 983 N mm2 mm2 Vibrations at the Hand Controls m s2 09 m s2 ISO 5349 1 Gradeability Transport 2 1 159 Gradeability Cleaning 2 1 159 Form Number 56043150 Page 16 service Manual 5 750 SC800 SC 750 ST 50800 ST Machine Maintenance MAINTENANCE ITEM Daily Weekly Monthly Charge Batteries Check Clean Tanks amp Hoses Check Clean Rotate the Brush es Pads Check Clean the Squeegee Check Clean Vacuum Shut Off Float Empty Clean Debris Tray In Re X covery Tank Clean Hopper on Cylindrical X System Check Each Battery Cell s Water Level does not apply to gel cell batteries Inspect Scrub Housing Skirts mM Inspect and clean Solution Filter mM Clean Solution Manifolds on Cylindrical System Purge Detergent System EcoFlex only Lubricate the Machine mM Check Carbon Brushes mM Replace Isolators REV only lo ___ __ _ _ Note See the individual machine system sections for maintenance information Check Carbon Brushes Check vacuum motor carbon brushes Qty 2 once a year or after 300 operating hours e Check brush and wheel drive motor s carbon brushes Qty 4 per motor once a year or after 500 operating hours e original new length of each carbon brush is 1 25 4mm on all 24 volt machine models brush and wheel drive motors e motors Replace carbon brushe
15. Vacuum Wand Switch Key Switch Main Power Switch Identification e Key Switch Main Power Turns ON the power to the control panel is OFF and I is ON Solution Switch Low Medium amp High Pressing the switch forward turns on or increases the flow of cleaning solution to the floor Pressing the switch backward turns off or decreases the flow of cleaning solution to the floor Note Solution will not flow until the machine begins to move Vacuum Wand Switch Pressing the switch forward turns the vacuum motor Pressing the switch backward turns the vacuum motor off e Scrub Switch o Cylindrical Models Pressing the switch forward lowers the scrub deck and enables all scrub functions Pressing the switch backward disables all scrub functions and raises the scrub deck o Disc Models When first pressed forward all scrub functions are enabled If in the normal scrub pres sure mode already pressing the switch forward will extend the deck actuator to the extreme scrub pressure mode which also increases the solution flow When operating in the extreme scrub pressure mode pressing the switch backward will retract the deck actuator to the normal scrub mode which also decreases the solution flow When operating in the normal scrub pressure mode pressing the switch backward disables all scrub functions and raises the scrub deck Form Number 56043150 Page 13 se
16. 1 Empty recovery tank 2 Press the scrub button to lower the brush head 3 Ifthe actuator does not move slightly raise the brush head with a jack to take tension off of the mounting hard ware 4 Lift recovery tank up 5 Disconnect electrical connector so the actuator will not move and then turn the key off Lower Fastener 7 Remove actuator 8 Reassemble in reverse order Form Number 56043150 Page 98 service Manual SC750 SC800 SC 750 ST SC800 ST Brush Motor 1 Remove the rear Scrub Brush 2 Remove the Debris Hopper 3 Remove the Brush Drive Belt 4 Lower Brush Head 5 Reconnect Battery Pack Connector 6 Turn the key on press the scrub switch and wait for brush head to lower 7 Unplug Brush Head Actuator electrical connector turn the key off and unplug the Battery Pack connector 8 Remove the motor strap strap Mounting Bolt 9 Remove the motor end mounting bolts Form Number 56043150 Page 99 service Manual SC750 SC800 SC 750 ST SC800 ST 10 Partially remove motor for better access to the wiring terminals 11 Do not lose the spacer plate 12 Record the wiring connections so that you will be able to reconnect it properly upon reassembly 13 Remove wiring 14 Use a backup wrench when removing attaching nuts to prevent the terminals from spinning 15 Reassemble in reverse order Form Number 56043150 Page 100 service Manual SC750 SC800 SC 750
17. 36 2 cm Form Number 56043150 Page 61 service Manual 5 750 SC800 SC 750 ST 5 800 ST Wiring Diagram 56112170 Rev D Complete Machine SC750 and SC800 The first page is a complete view When viewing on a computer it can be enlarged to be legible while retain ing the convenience of a single page The following pages are the same diagram enlarged on two pages so that they are legible when printed i BAT RED RED BLK FUSE 150 A BATTERY 24 VDC RED ORG CIRCUIT BREAKER 30 AMP OPTIONAL gt A3 ON BOARD BATTERY CHARGER BLK B SPE MODEL 2 0 24 25 B INTERLOCK IN INTERLOCK DUT SERIAL COMM J6 1 J6 2 26 3 WHT BLU SW SPST KEY WHT BEN BRN C82 53 RED YEL BRN BRN CIRCUIT BREAKER 10 AMP YEL BRN 28 14 KEY SWITCH INTERLOCK 3 4 BRN eee KEY SW IN B J3 1 3 rorrev J3 6 WHT RED 4 3 QUT YEL J3 8 5 BLK status 33 7 WHT ORG 44 10 status 1 CONTROL BOARD ev 23 5 JAIU Ae ACTUATOR MOTOR PG DRIVES SPEED CONTROLLER M2 MODEL 124 70 BRN
18. Brush Remove Contactor Coil Circuit Stuck On Corrupt Communication From On Board Battery Charger Form Number 56043150 Explanation Code Setting Conditions Flash Indicator Disables Check The Main Machine controller is sensing current flow through its internal switch for the solution solenoid cir cuit when it has not requested that the switch be turned on Senses gt 20 m Amps for 5 seconds The Main Machine controller is sensing current flow through its internal switch for the Brush Contactor Coil circuit when it has not requested that the switch be turned on Senses gt 20 m Amps for 5 seconds The Main Machine controller is sensing current flow through its internal switch for the Vacuum Contactor Coil circuit when it has not requested that the switch be turned on Senses gt 20 m Amps for 5 seconds The Main Machine controller is sensing current flow through its internal switch for the Brush Remove Contac tor Coil circuit when it has not requested that the switch be turned on Senses gt 20 m Amps for 5 seconds The Battery Charger did not properly repeat the charging profile message back to the Main Machine Controller Page 25 service Manual 5 750 SC800 SC 750 ST 50800 ST Service Test Mode Some outputs like the scrub brush motors are only turned on when other conditions are met such as when the ma chine is moving It can be difficult to check for voltage to the scrub brush motors
19. Form Number 56043150 Page 89 service Manual 5 750 SC800 SC 750 ST 50800 ST scrub System Disc and Cylindrical Switch Brush Contactor Retracted Wht Middle Extended Brush Head Actuator Main Machine Shown in retracted Controller position Drive Motor Controller Form Number 56043150 Page 90 service Manual 5 750 SC800 SC 750 ST 5 800 ST Component Locations e Brush Head e Debris Hopper Idler Assembly e Brush Drive Belt e Brush Head Actuator Brush Drive Motor Brush Head Actuator Form Number 56043150 e Brush Contactor e Brush Drive Motor e Motor Drive Pulley e Brush Drive Pulley Debris Hopper Motor Drive Pulley Brush Drive Pulley Page 91 service Manual SC750 SC800 SC 750 ST SC800 ST Form Number 56043150 Page 92 service Manual 5 750 SC800 SC 750 ST SC800 ST Troubleshooting Scrub Motors Do Not Turn On Possible Causes e Brush Contactor o Open or shorted winding Burned contacts e Wiring e Main Machine Controller Not energizing the brush contactor Drive Motor Controller Not providing machine moving signal Brush Head Will Not Raise or Lower Possible Causes e Mechanical binding for the actuator linkage e Brush Head Actuator Check both the motor and the position switches Only one position switch should be open at a time and it should open at the correct position o Actuator Motor Unplug the
20. To exit the service test mode Turn the Key Switch off Output Tests Brush Deck Lift Actuator Press the Scrub Switch forward to move the actuator downward to the next position Watch for the actuator to move Press the Scrub Switch backward to move the actuator up one position The Scrub Indicator LEDs indicate the current actuator position Neither LED is ON when deck is raised lower LED is ON when deck is at low scrub pressure both are on for high pressure Machines with disc scrub decks have three positions while cylindrical decks have only two Note If the switch inputs are not reporting correct information the controller will not understand the current actuator position and will not attempt to move the actuator Solution Solenoid Press the Solution Switch forward to cycle the solution solenoid on and off The high solution flow indicator will be on while in the test mode Listen for the Solenoid to click on and off Press the Solution Switch forward again to stop cycling the solenoid Brush Motor Contactor Press the Solution Switch backward to energize the brush motor contactor The medium solution flow indicator will be ON when energizing the contactor Listen for the contactor to click and look to see if the brushes are rotating Press the Solution Switch backward again to de energize the contactor Vacuum Motor Relay Press the Vacuum Switch forward to energize the Vacuum Motor Relay The Vacuum Indicator will be ON when en
21. 2 REMOVE 017 BRN FROM 53 AND PLUG INTO 010 BRN AT X66 emu EH M PUEDE SIUPHICERURHE eee 3 INSTALL 009 WHT BRN INTO S3 PIN 1 BN 7 010 BRN POR AL IESMINALS MUSI COMPLY ELE ULISS service Manual 5 750 SC800 SC 750 ST SC800 ST mr a De m 012 WELDING BLK 1 R2 R1 100K OHM 5K OHM SPEED LIMIT THROTTLE 9 7 Form Number 56043150 Ba 50 19 2 X20 008 RED 10 xe 17 10 X18 014 RED 16 TEE LR GNE 020 YEL 18 029 BRN 18 018 6 015 10 K1 VAC 29 as c RO 1 i X351 KO x74 BRUSH 71 CS 4 27 033 WHT 18 054 GRA ORN 18 059 BLK 18 060 BLK 18 074 BLK 18 a 012 WELDING BLK 1 _ E o ze 072 BLK 69 4 58 065 BLK 18 E x62 X61 70 070 WELDING BLK 6 052 BLK 10 076 BLK 12 076 BLK 12 HASSIS BONDING ELECTRICAL PANEL 5 053 GRN YEL 16 075 GRN YEL 16 068 GRN YEL 16 Page 69 service Manual 5 750 SC800 SC 750 ST 50800 ST x46 BATT kas X41 40 24 VDC 005 ORN 10 53 SW SPST KEY 009 WHT BRN 18 CONNECTION be X11 X51 3X52 011 BRN 18 i 2 1 0 YEL BRN 1 021 BRN 1
22. stalled and plugged into an AC outlet the input function of this signal is overridden and instead becomes a 1 wire bidirectional serial com munication line between the PC board and the on board charger J3 Connector Circuit Description Normal scrub position Other posi tions 0 5mV 4 96V 2 91V Value Comments Extra scrub pressure position Other positions 7 95mV If the Battery Charger is plugged in voltage pulses then settles in around 12V 1 Battery lead With vacuum motor running Battery lead With vacuum motor running Brush Remove contactor output When energized Otherwise 24V On Board Charger Interlock input input key switch voltage when on board battery charger is not plugged into AC outlet floats open when on board charger is plugged in Reverse Direction input from Speed Controller input GND when moving in reverse Form Number 56043150 Key on and Charger NOT plugged in When Charger is plugged in drops to 116mV In Reverse In Neutral or Forward 2mV 23V Page 52 service Manual 5 750 SC800 SC 750 ST 5 800 ST Circuit Description Fwd Reverse input from Speed Controller input 4mV In Forward or Reverse Both GND when moving in forward or reverse 24 1V In Neutral Speed Controller Status input input pulses 121mV Normal No faults Voltage pulses Both between B and GND to indicate error status when fault is present from Speed Controller 9V
23. 1 kg Brush Head Actuator Amp Draw Upward with weight of deck Approximately 2 3 Amps Brush Contactor Winding Resistance 55 ohms Gas Spring Force 112 pounds 500 N Form Number 56043150 Page 115 service Manual 5 750 SC800 SC 750 ST 5 800 ST Scrub System Rev Functional Description Scrubbing The scrub system moves the scrub head up and down and turns the scrub motors on and off at the operator s request to provide floor scrubbing action The discs spin toward the center at the front edge of each disc The head is moved up and down by an electric actuator motor that has integrated position switches The weight of the scrub head provides the downward pressure in the normal scrub mode When extreme pressure is requested the actuator moves down farther Causing a gas spring to exert additional downward pressure on the floor The Main Machine Controller energizes the brush solenoid to turn on the brush motors when the following inputs have been met e Key switch on e Operator request e Machine moving signal FOR REV is received from the Drive Motor Controller A2 PG Drives Speed Controller o Approximately 24 volts received from the main controller J3 Pin 6 is switched to battery negative by the Drive Motor Controller dropping the voltage to 0 volts Here is how the circuit works for the scrub motors The Main Machine Controller turns on the scrub motors indirectly by energizing the brush contacto
24. 18 Form Number 56043150 Page 75 service Manual 5 750 SC800 SC 750 ST SC800 ST Page 3 of 3 53 Z WIRING DIAGRAM SHOWN WITHOUT ON BOARD 019 YEL CHARGER IF CHARGER IS INSTALLED MAKE 009 WHT BRN MAKE WIRING CHANGES AS NEEDED 022 YEL BRN 1 MOVE WIRE 022 YEL BRN TO 83 PIN 2 X66 2 REMOVE 017 BRN FROM S3 AND PLUG INTO 010 BRN AT X66 m gt gt 3 INSTALL 009 WHT BRN INTO S3 PIN 1 001 10 002 BLK 10 X10 X42 ON BOARD X40 004 WELDING BLK 1 BATTERY CHARGER Bt OPTIONAL gt 5 MODEL HF2 U124V25A 1N INTERLOCK SERIAL COMM 5 M5 rani VAC 3 JO 09 WHT BR 88 Ens a 010 BRN 18 024 WHT 12 ae 025 BL 88 VALVE SOLENOID 005 ORN 10 X35 J4 1 THROTTLE WIPER J4 eTHRHTTLE HIGH REF J4 3 AUX2 24 5 KEY SW IN 2 PG DRIVES SPEED CONTROLLER MODEL 124 70 J4 8 THROTTLE LOW REF J4 9 SPEED LMT WIPER J4 10 STATUS OUT 1 J4 11 AUX3 J4 12 REV SW IN NOT USED J4 13 OVCNOT USED JS 2 J5 8 AUX1 39 00 0039 50 e 3 NITE WIRING DIAGRAM SHOWN FO R DISC BRUSHES LEADS NEED TO BE 010 BRN FLIPPED IN POLARITY LEFT BRUSH MOTOR CYLINDRICAL BRUSHES 006 WHT 10 K 12 DECK ACTUATOR M2 52 51 50 BRUSH JE
25. 7 Battery lead With vacuum motor running Solution Solenoid Valve winding 116mV When energized Hold solution but Both ton down 12 Vacuum Contactor winding 4 9V When energized voltage initially Both drops to 90mV then settles at 4 9v This is due to 100 on time at first to pull in the contactor which is then reduced to 80 to hold it in 13 Brush Motor Contactor winding 4 When energized voltage initially Both drops to 90mV then settles at 4 9v This is due to 100 on time at first to pull in the contactor which is then reduced to 80 to hold it in 14 Key Switch input input B voltage when key is 24 9V Key On or Off with on board battery Both turned on charger Form Number 56043150 Page 53 service Manual SC750 SC800 SC 750 ST SC800 ST Electrical System Functional Description General The electrical system is powered by four 6 volt batteries for a total of 24 volts Heavy cables connect the batteries in series A large red Main Battery Pack Connector provides battery power to the machine wiring On machines without an on board battery charger the Main Battery Pack Connector is used for hooking up the batteries to a shelf battery charger unit To prevent damage to the batteries due to excessive discharging the control system will turn off the scrub system and the recovery system as the battery voltage drops too low A steel plate at the back of the solutio
26. Detergent Chemical Mixing system and what brand to display upon power up If it is equipped it also needs to know what geographic location the machine is used in for displaying the detergent ratio as expected in that region North America mode Shows chemical ratio using X XXX notation example 1 300 and the Advance brand upon power up for the Americas market North South and Central America Global mode Outside of North South and Central America Shows chemical ratio using percentage notation example 0 396 and the Nilfisk Advance brand upon power up In off mode the chemical icon and ratio are not displayed on the LCD e ONBOARD CHEMICAL N AMERICA CHEM MODE e GLOBAL CHEM MODE To change the setting 1 Scroll through the menu using the Solution Increase and Decrease switches until you get to the desired value 2 Tosave and go back to the main menu press the scrub ON OFF switch Form Number 56043150 Page 34 service Manual 5 750 SC800 SC 750 ST 5 800 ST DETERGENT MODE This function is used to configure the way the EcoFlex system behaves or to disable it Different geographic locations desire different EcoFlex behavior This mode provides the ability to match the behavior to market area desires e OFF Disables EcoFlex feature e MODE 1 Expected be used in combination with CHEM MODE e MODE 2 Expected to be used alone or in combination with GLOBAL CHEM MODE To change the setting 1
27. Models Early 38 Main Machine Controller SC750 ST 5 800 ST Models Later 40 Main Machine Controller SC750 5 800 Models Early Build 40 Main Machine Controller SC750 and 5 800 Models Later build 44 Rocker Switches ST 50 45 32 5 3 51 Shop Measurements Main Machine Controller a 51 24 49 RE OR Oa ee aa 54 Functional Description gt s s s s sa s ek enti E X o 40 30 wk Wow ae GD 54 54 On board Battery Charger sas 58 Row a oko XX Ao RUE ow Fm X we 55 Component 3 s sd eee EURO e eaea X Ao dod 57 Electrical Panel Components ssi RR ERED RED OR e X X X X Xx amp o 43 58 Maintenance and Adjustments 59 Battery Maintenance and ne xi hwibowhew hae bau bee Rok x 4 xl ox 59 59 Insufficient Machine Operation Time 0 0 29 The Battery Charger Does Not 29 Removal and Installation uu
28. REV SW IN NOT USED WHEEL EE GRA X21 5 T T 88 2 DNE J5 a NU CONNECTION X81 X82 X33 x82 5 069 BRN 18 X12 500 73 56 poem _ 073 GRA 1 E H UE REVERSE SW X75 J5 8 AUXI QUT gt s a bbw we E 3 s TRANSAXLE 06 075 GRN YEL 16 208 2 lt F 5 522452 X34 5 Pod nE 588855 BLK 5 5 058 BLK 18 i ES dn a 18 012 WELDING BLK 061 BLK 18 44 072 BLK 10 X69 NU 070 WELDING BLK 6 052 BLK 10 076 BLK 12 076 BLK 12 1 2 025 BLK 12 SP1 062 YEL RED 18 ELECTRICAL PANEL X3 lt E 068 GRN YEL 16 WIRING DIAGRAM SHOWN FOR DISC BRUSHES LEADS NEED TO BE FLIPPED IN POLARITY ON LEFT BRUSH MOTOR FOR CYLINDRICAL BRUSHES 3 WIRING DIAGRAM SHOWN WITHOUT ON BOARD 019 YEL CHARGER IF CHARGER IS INSTALLED MAKE 009 WHT BRN MAKE WIRING CHANGES AS NEEDED 022 YEL BRN 1 MOVE WIRE 022 YEL BRN TO 53 PIN X66 2 REMOVE 017 BRN FROM S3 AND PLUG INTO 010 BRN AT X66 3 INSTALL 009 WHT BRN INTO 53 PIN 1 017 BRN 010 BRN service Manual 5 750 SC800 SC 750 ST SC800 ST Page 1 of 3 005 ORN 10 50 AMP X20 Pe ues X42 F1 008 RED 40 LR m SW SPST KEY Bex WELDING RED 1 X1 xe CB2 CONNECTION 003 WELDING RED 1 04 WELDING BLK 1 0
29. SC800 ST Models Early Build Note Electronic devices like the Main Machine Controller are sensitive to Electrostatic Discharge ESD Before handling the controller touch a metal bench or shelf to discharge any electrical charge that may have built up in your body Do not walk around with a controller in your hands 1 Empty recovery tank Turn off key 2 Remove upper handle mounting bolts loosen lower mounting bolts and pivot handle assembly downward 3 Remove circuit breaker mounting nuts 4 Remove circuit breaker mount plate screws Partially remove plate Remove breakers from plate then turn plate and insert into cover opening Remove Circuit Breaker Mounting Plate 5 Remove electrical panel cover mounting screws Form Number 56043150 Page 38 service Manual SC750 SC800 SC 750 ST SC800 ST Tip cover away from machine and disconnect electrical connectors from the Main Machine Controller and Key 6 Switch Remove the control switch interface panel ground screw a Place electrical panel cover on work bench Disconnect the ribbon connector to the control switches Note the orientation of the ribbon to the wiring connector n Ch Control Panel _ 48 95 5 9571 fey 8 95 Ribbon EH inen Egi 30411211 5_ 4 Gently push to release Page 39 Form Number 56043150 service Manua
30. ST SC800 ST Motor Carbon Brushes 1 Remove the brush drive motor 2 Mark the position of the endplate to the motor casing for reassembly 3 Remove the 2 through bolts and pry off the endplate assembly 4 Replace the carbon brushes a Observe how the springs roll when the brush is pushed back before taking it apart b Remove a brush and spring c Install a new brush and spring into the brush holder Thread the brush wire lead through the brush holder Position the back end of the brush in the cup of the spring so that the spring will unroll as the brush is pushed back once it is installed side ofspring Spring unrolls on this side held open Form Number 56043150 Page 101 service Manual SC750 SC800 SC 750 ST SC800 ST d Push brush back against the spring and insert a stiff temporary retaining wire paper clip through the ac cess hole in the end cover Remove silicone sealer from the holes The wire must go through the holes in the brush holder just in front of the brush to hold the brush back against the spring pressure Push Brush 2 r Insert Against Spring Retainer Retaining Wire 5 Install the other three brushes 6 Install the wave washer V s T ioca 8 7 Install the end cover in stages aligning the marks made earlier a Install it far enough so that the brushes will contact the commutator when the temporary retaining wi
31. Service Manual is a resource for professional service technicians It provides information for understanding how the machine operates where components are located basic troubleshooting maintenance and mechanical service opera tions Pictures in this manual are of prototype machines If a picture is slightly different than the machine you are working on it is likely that an improvement was introduced This manual covers the Nilfisk SC800 models as well as Advance SC750 SC800 SC750 ST and SC800 ST models Each ma chine has as specific model number part number which can be found on its nameplate The cover page of the manual lists each machine part number that the manual applies to Compare the model number of the machine you are working on to the model numbers listed on the cover page to be sure you are using the correct manual This manual often distinguishes between ST models and Non ST models Model names that end in ST SC 750 ST SC800 ST use palm drive switches on the drive handle and have toggle switches on the control panel Models that do not end in ST SC 750 SC 800 use a drive paddle and have solely membrane style switches on the control panel Non ST Model Control Panel with Membrane Style Switches ST Model Palm Drive 2 Switches Control Panel with 24 amp Toggle Switches Form Number 56043150 Page 6 service Manual 5 750 SC800 SC 750 ST SC800 ST Other Re
32. WHE BOARD CHARGER IS USED REMOVE BRN WIRE FROM KEY SW CONNECT TO BRN WIRE FROM BATTERY CHARGER amp REPLACE WITH WHT BRN FROM CHARGER ALSO MOVE YEL BRN WIRE AT KEY SWITCH FROM BRN 1 Form Number 56043150 Page 63 service Manual 5 750 SC800 SC 750 ST 50800 ST BLK BLK ORG BLK BLK BRN BRN J4 5 KEY SW IN WHT RED J4 3 BLK WHT ORG 44 10 status DUT WHT BLK J4 1l NUX3 Ae PG DRIVES SPEED CONTROLLER ODEL 124 70 BRN BRN J4 9 SPEED LMT WIPER Es as lt lt WHT 44 2 THROTTLE HIGH REF M1 GRN POT SPEED LMT FAST R FAST 100K EN le BLU X BLU 4 1 THROTTLE WIPER POT THROTTLE MOTOR WHEEL DRIVE SLOW R1 5K Mt BLK SLOW BLK J4 8 THROTTLE LOW REF J9 gut M2 GRA AS LASER MODULE BRN B OPTIONAL gt B CRA J4 13 0 voLTS ec PINK 54 12 REV SWITCH IN BLK BLK BLK m OPTIONAL gt BRN BRN 4 BLK HOUR METER 3 4 N C BLK WHT WHT 1 BLK Form Number 56043150 Page 64 service Manual 5 750 SC800 SC 750 ST 50800 ST Wiring Diagram 56112180 REV C Complete Machine SC750 ST and SC800 ST The first page is a complete view When viewing on a
33. a blink code on the fault code indicator light The code will be a two digit code The first digit will flash out followed by a short pause Then the second digit will flash out followed by along pause On short pause On On long pause is a code 1 2 If multiple codes are present the codes will appear in order until all have been displayed Then the sequence will repeat again Fault Code Table For SC750 and SC800 models refer to the column LCD Display Code For SC750 ST and SC800 ST models refer to the ST Blink Code column LCD ST Code Explanation Code Setting Conditions Flash Indicator Disables Check Display Blink Definition Code Code 2 1 1 Speed Control Fault The Drive Controller is communicating that it sees a problem The drive controller does not store specific drive system fault codes Disables Detergent Solution Brush Motors tor linkage shorted wiring 12 Scrub Deck Lift Actuator Excessive current draw was sensed Code sets at Circuit Over Current mately 5 8 amps or more Disables Brush Head Actuator Check for shorted actuator mechanical binding of actua Form Number 56043150 Page 22 service Manual 5 750 SC800 SC 750 ST 50800 ST LCD ST Code Explanation Code Setting Conditions Flash Indicator Disables Check Display Blink Definition Code Code Brush Motor Circuit Excessive current draw was sensed Code sets at approxi Over Current
34. actuator connector and momentarily supply fused 24v power and ground to two motor terminals to see if the motor will operate Machine harness wire color Pink wire and Gray wire Reverse the polarity to drive it in both directions If the motor will not drive in both directions replace the actuator If it does drive in both directions proceed to check the position switches o Position Switches Access the Main Machine Controller and unplug the electrical connectors Checkthe retracted position switch e Putthe black ohmmeter lead on the Brown wire at the J2 connector pin 2 e Putthe red ohmmeter lead on the White wire at the J2 connector pin 3 Form Number 56043150 Page 93 service Manual 5 750 SC800 SC 750 ST 50800 ST e Drive the actuator motor all the way up and down using jumper wires powered by bat tery positive and negative Connect them to the two actuator motor wires at the Main Machine Controller connector Pink wire at connector J1 pin 4 and Gray wire at connec tor J1 pin 5 Change polarity to change direction Immediately remove jumper wires at the end of motor travel e Monitor the ohmmeter It should show an open circuit no continuity only when the actuator is in the retracted position In all other positions it should show a closed circuit continuity Check the middle position switch Put the black ohmmeter lead on the Brown wire at the J2 connector pin 2 Put the red ohmmeter lead on the Yell
35. and vacuum based on operator requests and other inputs It is located directly behind the operator control panel It is capable of storing and display ing many fault codes In addition to fault codes it supports special modes of operation called Programming Mode and Service Test Mode The programming mode is used primarily for telling the controller how the machine is equipped so that it can operate accordingly The service test mode is a powerful and convenient diagnostic feature that allows a technician to request specific outputs to operate regardless of current inputs The Drive Motor Controller Speed Controller operates the drive motor that propels the machine based on operator requests See the section on Wheel System Traction for more information Form Number 56043150 Page 20 service Manual SC750 SC800 SC 750 ST SC800 ST Component Locations Electrical Panel Cover Circuit Breaker Mounting Plate Control Switch Interface Panel Main Machine Controller Main Machine Controller Behind Cover Electrical Panel Cover Form Number 56043150 Control Switch Interface Panel Circuit Breaker Mounting Plate Page 21 service Manual 5 750 SC800 SC 750 ST 50800 ST Troubleshooting Fault Codes 5 750 and SC800 models Any error codes detected by the Main Machine Controller will be displayed on the LCD display as they occur SC750 ST and SC800 ST models Active faults are displayed as
36. brush head by removing the plastic cover and the attaching nut a 4 z Installation 1 Apply Loctite blue 243 threadlocker or equivalent to the threads of each isolator 2 Install the isolators in the brush head Position each one so that the color stripe it will be visible when the motor plate is installed Torque each nut to 8 10 ft Ibs 10 8 13 5 N m Install the 4 plastic covers over the nuts 3 Apply Loctite blue 243 threadlocker or equivalent to the threads of each isolator Install the motor plate and 4 isolator nuts Torque each nut to 8 10 ft Ibs 10 8 13 5 N m Ensure that the isolator rubber does not twist when you tighten the nuts Visually inspect the color stripe to make sure that it is straight line and not twisted If it is twisted loosen the nut and repeat the procedure It may be necessary to hold the isolator in position with your hand while tighten the nut Form Number 56043150 Page 126 service Manual SC750 SC800 SC 750 ST SC800 ST Scrub Motor Carbon Brushes 1 Remove the brush head from the machine 2 Remove wire retaining nut and rubber packing em M D EN a i E 4 gt Form Number 56043150 Page 127 service Manual SC750 SC800 SC 750 ST SC800 ST 5 Replace the carbon brushes a b C d 6 Observe how the springs roll when the brush is pushed back before taking it apart
37. cage seals off the vacuum port when the tank is full to protect the vacuum motor from water ingestion When the float ball seats the amp draw of the motor is reduced and the Main Machine Controller shuts off the vacuum motor The squeegee is raised and lowered manually using the squeegee lift lever Sorings apply downward pressure on the squeegee Here is how the vacuum motor circuit works The relay winding is fed battery voltage on terminal 85 The other side of the relay coil terminal 86 is connected to a switch inside the controller To energize the relay the controller closes the switch which completes the path to B The relay contact terminal 30 is connected to B When the relay is energized the contacts close connecting 30 to 87 which sends battery voltage to the vacuum motor Since the other side of the motor is connected to battery negative the motor turns on The Main Machine Controller also monitors the current draw of the vacuum motor via a vacuum motor sense wire The controller has an internal voltmeter that measures the voltage difference drop between the sense wire and battery negative A calibrated ground wire of a specific size and length is used for the motor ground At a given amperage flow there is a correlating voltage drop As the amperage increases the voltage drop also increases The controller translates the voltage drop measured into amperage Vacuum Motor Control Circuit Vacuum Motor 87 30 B M
38. interface and carefully turn the cover over Remove 4 screws securing circuit board Main Machine Controller to cover Remove the control switch interface panel and circuit board together through the cover opening 10 If the board is being replaced you will need to use a new pressure sensor tube or transfer the existing tube from the old board Follow the steps below to transfer the tube Form Number 56043150 Page 42 service Manual 5 750 SC800 SC 750 ST 5 800 ST a Useasmall sharp knife to cut the tube off near the sensor on the board 1 mm from sensor b Make a shallow slit with the knife along the length of the clear tube that is still attached to the sensor port Do not press too hard and avoid cutting into the sensor port Make 3 or 4 passes with the knife pressing softly rather than one hard cut See the photos below Toinstall the sensor onto a new PCB assembly grasp the tube near the end with your fingers and slowly push the tube onto the sensor port Do not push too hard or the sensor may break Form Number 56043150 Page 43 service Manual 5 750 SC800 SC 750 ST 5 800 ST 11 Reassemble in reverse order taking care not to damage the printed circuit ribbons used to connect the circuit board to the control switch interface panel If you did not drain the solution tank earlier you must do so before connecting the pressure sensor hose in order for the solution level gauge to work properly M
39. kg ery tanks Static Wheel Pressure right front PSI N mm2 59 08 psi 407 N mm2 Static Wheel Pressure left front PSI N mm2 60 1 psi 414 N mm2 Static Wheel Pressure center rear PSI N mm2 287 6 psi 1 983 N mm2 Vibrations at the Hand Controls m s2 09 m s2 ISO 5349 1 Gradeability Transport 2 1 159 Gradeability Cleaning BEEN 296 1 159 h Form Number 56043150 Page 15 service Manual 5 750 SC800 SC 750 ST 5 800 ST Machine Specifications SC800 and SC800 ST See other system chapters for specifications not listed here Model Name Model Number SC 800 SC800 ST Battery Capacity 242 310 312 Solution Tank Capacity Gal L 24 69 gal 93 5 Recovery Tank Capacity Static Gal L 26 84 gal 101 6 Sound Pressure Level dB A 61 IEC 60704 1 Gross Weight standard machine w full solu tion tank empty recovery tank and E U batteries lbs kg 996 165 451 77 kg installed Net Weight standard 28 disc machine w o op tions batteries or removable brushes w empty lbs kg 363 lbs 169 2 kg solution and recovery tanks Net Weight standard 34 disc machine w o op tions batteries w empty solution and recovery Ibs kg 365 Ibs 170 1 kg tanks Net Weight standard cylindrical machine w o options batteries or removable brushes w empty lbs kg 373 lbs 173 7 kg solution and recovery tanks Static Wheel Pressure right front psi N Static Wheel Pressure left front psi N
40. mately 60 amps or more 1 3 Check for shorted motor mechanical binding of motor shaft current sense wire connections ground connec tions Vacuum Motor Circuit Excessive current draw was sensed Code sets at approxi Over Current mately 25 amps or more ass I Check for shorted motor current sense wire connections ground connections 1 5 Solution Solenoid Circuit Excessive current draw was sensed Code sets at approxi Over Current mately 0 7 amps or more Check for shorted solenoid winding shorted wiring Vacuum Contactor Coil Excessive current draw was sensed Code sets at approxi Circuit Over Current mately 0 1 amps or more Check for shorted contactor winding shorted wiring Brush Contactor Coil Excessive current draw was sensed Code sets at approxi Circuit Over Current mately 0 7 amps or more Check for shorted contactor winding shorted wiring N A Detergent Pump Circuit Excessive current draw was sensed Over Current Check for shorted pump winding shorted wiring Brush Remove Contactor Excessive current draw was sensed Code sets at approxi Coil Over Current mately 0 1 amps or more lt N gt Check for shorted contactor winding shorted wiring 2 3 Solution Solenoid Circuit The Main Machine Controller has turned the solution Open solenoid circuit on but it is not sensing any current flow Senses lt 20mAmps for 5 seconds Check for open solenoid winding open wiri
41. position In all other positions it should show a closed circuit continuity Check the extended position switch Put the black ohmmeter lead on the Brown wire at the J2 connector pin 2 Put the red ohmmeter lead on the Green wire at the J2 connector pin 12 Drive the actuator motor all the way up and down using jumper wires powered by bat tery positive and negative Connect them to the two actuator motor wires at the Main Machine Controller connector Pink wire at connector J1 pin 4 and Gray wire at connec tor J1 pin 5 Change polarity to change direction Immediately remove jumper wires at the end of motor travel Monitor the ohmmeter It should show an open circuit no continuity only when the actuator is in the extended position In all other positions it should show a closed circuit continuity e Main Machine Controller Form Number 56043150 Page 121 service Manual SC750 SC800 SC 750 ST SC800 ST Removal and Installation Brush Head 1 Turn key on and push scrub on off switch to lower the brush head to the floor Then turn the key off and discon nect the main battery pack connector 2 Disconnect the wiring for both brush motors Note the wiring connectors near one motor are not both for the same motor They are one positive for each motor or one negative for each motor depending on which side you are working 3 Loosen the solution hose clamp and remove the hose from the brush head Remove the nut and bolt a
42. s WN _ BLK D MOTOR LEFT BRUSH POLARITY REV8 DECK MN MOTOR RIGHT BRUSH A WHEN ON BOARD CHARGER IS USED REMOVE BRN WIRE FROM KEY SW CONNECT TO BRN WIRE FROM BATTERY CHARGER amp REPLACE WITH WHT BRN FROM CHARGER BRN YEL Form Number 56043150 ALSO MOVE YEL BRN WIRE AT KEY SWITCH FROM Page 62 service Manual 5 750 SC800 SC 750 ST 50800 ST F1 BAT BLK RED RED Jp FUSE 150 A BATTERY 24 VDC RED ORG ORG CIRCUIT BREAKER 30 AMP OPTIONAL 2 A3 N BUARD BATTERY CHARGER BLK SPE MODEL 4 B INTERLOCK IN INTERLOCK OUT SERIAL COMM J6 1 J6 2 J6 3 WHT BLU SW SPST KEY WHT BRN BRUN CB2 S3 RED M E
43. settings and scrub pressure settings for each of the scrub deck types To check or change the setting 1 While pressing and holding the vacuum scrub and solution switches backward turn the key switch on 2 Wait about 3 seconds until all of the LEDs light up and then go off Release the switches The Regular Scrub Pressure and Heavy Scrub Pressure Indicators will remain on and the fault indicator will be flashing a numeric value that represents the current setting To change the setting press the solution switch forward to increase the value or backwards to decrease the value To save the setting press the scrub switch forward All LEDs will turn on then turn off the key switch e 1 blink 28 Inch Cylindrical Brushes e 2 blinks 26 Inch Disc Brushes 3 blinks 34 Inch Disc Brushes Battery Charger Selection This function is used to inform the Main Machine Controller whether not the machine is equipped with the optional on board charger If it is it is also used to inform the controller of what kind of batteries the machine is equipped with The Main Machine Controller will request a specific charging profile from the battery charger to match the batteries To check or change the setting 1 While pressing and holding the scrub and solution switches backward turn the key switch on 2 Wait about 3 seconds until all of the LEDs light up and then go off Release the switches The red battery Indicator will remain
44. strip connector to the switches Note the orientation of the ribbon and connector for reassembly 3 Disconnect the wiring from the switch you are removing Soluti p DU Scrub Vacuum Wand Switch Switch Switch 3 ORG GRN gt ORBLE b 2 1l ORG BRN 12 ORG BLK 1 ORG YEL 4 Push the switch retaining lock tabs located at each corner and push the switch back through the cover 3 ORG RED 3 ORG GRY 2 ORG BLK 1 ORG BLU 2 ORG BLK 5 Install the switch by pressing it into place 6 Reinstall the wiring and finish reassembling in the reverse order of disassembly Form Number 56043150 Page 50 service Manual 5 750 SC800 SC 750 ST 50800 ST Specifications Shop Measurements Main Machine Controller The following tables contain some real world shop voltage measurements to help you recognize what normal looks like All voltage values were measured with the black Negative voltmeter lead connected to the main battery negative terminal unless otherwise specified Non ST SC750 and SC800 models ST SC750 ST and SC800 ST models J1 Connector Circuit Description aee Brush Head Actuator motor output 24 With red lead at pin 4 black down lead at pin 5 5 Brush Head Actuator motor output Both 24v up ww rese gt Ls
45. t 183025 1 x T x EE S ux 5 55 5 1 S 5 LI L 003 WELDING RED AE X40 004 WELDING BLK 1 HHH 005 10 65 ull SW SPST KEY CONNECTION 011 WHT BLU 18 512 X52 017 BRN 18 did 555 28 QS Eu EI e eee Be RR c 1 12 FE ES X72 12 SSS GG SS BRN 18 R 021 BRN 18 023 BRN 18 028 BRN 18 les s 026 BRN 18 005 ORN 1 Al CONTROL BOARD 2 3 4 5 6 7 8 9 10 11 12 24 1 THROTTLE WIPER J4 2THROTTLE HIGH RE J4 3 AUXe OUT J 1 2 3 5 6 9 J 2 3 9 10 11 J3 1 2 3 4 5 6 7 9 10 11 12 15 14 24 5 SW IN 8 EE 9527 855259529 2338 329 soos e 8 B 8 8 8 8 8 8 PG DRIVES SPEE CHASSIS BONDING MODEL OPERATOR INTERFACE x7 J4 8 THROTTLE LOW LL J4 9 SPEED LMT WIPE 2 E 555 J4 10 STATUS DUT 9 2 d 5 25865 25556 5856 J4 11 AUX3 OUT a 3 2 ea g 8 3 2 885 Sesh liste J4 12 REV SW IN NID 5 T To ees 8885 7 8 24 13 USED LE one 112 025 BLK 12 SP 1 062 YEL RED
46. the brush motors to remove the discs Vacuum Wand Switch Starts and stops the vacuum motor LCD Display B F1 Hour Meter e F2 Solution Tank Level Indicator e F3 Fault Codes e F4 Detergent Indicator if so equipped e F5 Detergent Ratio Indicator If so equipped e 26 Battery Indicator e F7 Recovery Tank FULL Indicator e F8 Battery Low Indicator Form Number 56043150 Page 11 service Manual SC750 SC800 SC 750 ST SC800 ST Indicator Lights All indicator lights illuminate for 2 seconds when the key is first turned on nome Soer Solution Flow Indicators Scrub Pressure Indicators Vacuum Indicator Detergent Indicator Burst of Power Indicator Form Number 56043150 No flow None lit Low flow Bottom one lit Medium flow Bottom two lit High flow All lit Regular Scrub Pressure Bottom one lit Extreme Scrub Pressure Both lit Vacuum on On Vacuum off Off Time Delay before shut off Flashing Detergent on On Detergent off Off Switch disabled Off Switch enabled On Green Burst of Power Flashing Yellow Page 12 service Manual SC750 SC800 SC 750 ST SC800 ST Control Panel SC750 ST and SC800 ST Toggle Switch Control Panel These machines use a control panel with 3 large toggle switches and do not have an LCD display See the following sec tions for switch identification and Indicator Light explanations Scrub Switch
47. the desired value 2 save go back to the main menu press the scrub ON OFF switch DISPLAY REV LEVEL Used to display the software revision This is not a setting that can be changed After viewing the revision value press the scrub on off switch to return to the main menu FAULT RECALL This function is used by a technician to check for historical codes and clear them If no fault code is present the display should show a dash symbol If the solution on off button is pressed in the Fault Recall submenu the fault history shall be erased Press the scrub on off switch to return to the main menu FAULT DETECTION Normally the Main Machine Controller will perform checks of the electrical system during operation If a fault occurs in a particular system that system and possibly others will be shut down This can make troubleshoot ing the system difficult This option will allow service personnel to disable some of the fault detection checks to facilitate troubleshooting This will not disable the over current protection on any of the systems e ENABLED e DISABLED To change the setting 1 Scroll through the menu using the Solution Increase and Decrease switches until you get to the desired value 2 Tosave and go back to the main menu press the scrub ON OFF switch Form Number 56043150 Page 37 service Manual SC750 SC800 SC 750 ST SC800 ST Removal and Installation Main Machine Controller SC750 ST and
48. the level of the water directly It measures the pressure the water exerts on a pressure sensor through a sealed hose The higher the liquid level the more pressure is exerted on the sensor There is a pressure sensor mounted on the main machine control board with a clear hose that connects to a fitting on the solution tank On the other side of the fitting another hose goes into the tank When the tank is filled with water detergent the liquid tries to fill the hose but since the hose is sealed off it cannot displace the air in the hose and consequently cannot fill the hose with liquid It does exert pressure on the sensor which is converted to a voltage and read by the controller This is like holding your thumb over the top end of a drinking straw and inserting the straw into your soft drink The liquid does not enter the straw because the air cannot escape out of the straw What you don t notice with your thumb is that the air inside the straw is actually slightly pressurized by the liquid trying to displace the air On all machines the Main Machine Controller turns the solution flow on and off and meters the amount that flows via an electric solenoid valve based on operator request and whether or not the machine is moving The solution solenoid valve is spring loaded closed and must be energized to pull the valve open and allow solution to flow To control the amount of solution the controller cycles the solenoid on and off at a slow rate For
49. two switches Ov 2 Normal Scrub mode Middle Position switch 5v Other two switches Ov 3 Extreme Scrub mode Extended Position switch 5v Other two switches Ov Note The actuator extended position switch circuit is unique because it is also used as a communication line between the Main Machine Controller and the battery charger The addition of the battery charger on the circuit drops the 5v that is normally seen when the switch is open to approximately 3 volts This is normal When the key is turned off if the brush head is down the Main Machine Controller will raise the brush head to the full up position When the operator requests the scrub mode the controller drives the actuator down until it sees the Middle Position switch open 5v When the operator turns off the scrub function the controller drives the actuator mo tor up until it sees the Retracted Position switch open again 5v If more than one position switch is open 5v at a time the controller does not know which one to believe It realizes there must be a problem and will not move the actuator Form Number 56043150 Page 117 service Manual 5 750 SC800 SC 750 ST 50800 ST Functional Circuit Diagram Scrub System REV 2 o4 o mo Switch Brush Brush Motors Contactor Retracted Wht Middle Extended Brush Head Actuator Main Machine Shown in retracted Controller position Drive Motor Controller Form Number 5
50. weight of deck Approximately 2 Amps Brush Contactor Winding Resistance 55 ohms Gas Spring Force 112 pounds 500 N Form Number 56043150 Page 131 service Manual 5 750 SC800 SC 750 ST 50800 ST Solution System Functional Description The solution system dispenses water and detergent to the scrub brush head for scrubbing the floor The solution tank holds the solution and serves as the main body of the scrubber Solution from the tank flows through a manual shut off valve filter solution valve solenoid manifold and out to the deck Disc decks deliver the solution on top of the disc near the center On Cylindrical decks the solution is delivered through several small holes in manifold hoses along the front of the deck The solution then drips through holes in the deck in front of the forward brush The filter protects the solution valve from debris which can damage the valve The manual shut off valve makes it possible to service plumbing components without draining the solution tank The standard solution system requires the operator to mix a cleaning detergent with the water in the solution tank An electric solenoid valve is used to turn the solution flow on and off as well as to meter the amount of solution used The solution valve is controlled by the Main Machine Controller SC750 and SC800 models report solution tank liquid level information to the operator on the Control Panel LCD The system does not measure
51. while the machine is moving Also if voltage is not present it leaves in question what other conditions may not have been met yet The Service Test Mode solves these problems for the technician In Service Test Mode the technician can request that the Main Machine Con troller ignore all other conditions and directly turn on the scrub brush motors as well as other outputs Service Test mode can also be used to verify that certain inputs are seen by the controller The concept is the same for all models but the procedure is very different depending on whether you are working on an ST model control panel with rocker switches SC750 ST and SC800 ST or a non ST model control panel with membrane switches SC750 and 5 800 See appropriate sections below Service Test Mode SC750 ST and SC800 ST Models Control Panel with rocker switches To enter the service test mode Start with the battery charger unplugged and the key off 1 Hold all three switches Vacuum Scrub and Solution in the up forward position while turning the key 2 Wait approximately 3 seconds until all of the LEDs light up and then turn off The low solution flow indicator light should remain on to confirm that you are in the service test mode Now that you are in service test mode you can request that the controller operate the various outputs and verify certain inputs via the indicator light operation If a fault occurs the Fault LED will display the fault
52. wire at the J2 connector pin 12 Drive the actuator motor all the way up and down using jumper wires powered by bat tery positive and negative Connect them to the two actuator motor wires at the Main Machine Controller connector Pink wire at connector J1 pin 4 and Gray wire at connec tor J1 pin 5 Change polarity to change direction Immediately remove jumper wires at the end of motor travel Monitor the ohmmeter It should show an open circuit no continuity only when the actuator is in the extended position In all other positions it should show a closed circuit continuity Main Machine Controller Form Number 56043150 Page 111 service Manual SC750 SC800 SC 750 ST SC800 ST Removal and Installation Scrub Brush Brush Head 1 Remove plastic brush head covers 2 Remove scrub brushes 3 Loosen but do not remove the 3 brush head mounting fasteners 4 Turn the key on and press the scrub on off button to lower the brush head to the floor Then turn the key off leaving the brush head on the floor 5 Disconnect scrub motor electrical connectors 6 Disconnect the solution hose 7 Remove the 3 brush head mounting fasteners Remove Solution Hose 8 Pull brush head out from under the machine 9 Reassemble in reverse order Form Number 56043150 Page 112 service Manual SC750 SC800 SC 750 ST SC800 ST Scrub Motor Carbon Brushes Note Photos in this section were taken with the m
53. 0 ST LT BRUSH X56 A39 006 WHT 10 007 BLK 10 029 BRN 18 UATOR CIVNOILdO 4 JINGOW 43571 BRUSH 4 DECK CHASSIS BONDING X80 M4 RT BRUSH FG X56 X54 X4 032 WHT 18 053 GRN YEL 16 OPTIONAL Me CHEM PUMP 070 WELDING BLK 6 051 WHT 10 063 YEL ORN 18 losz BLU GRA 18 056 RED YEL 18 Form Number 56043150 Page 72 service Manual 5 750 SC800 SC 750 ST 5 800 ST Wiring Harness Configuration Diagram 56112181 REV SC750 ST and SC800 ST The first page is a complete view When viewing on a computer it can be enlarged to be legible while retaining the convenience of a single page The following pages are the same diagram enlarged on multiple pages so that they are legible when printed There is overlap across the pages When printed they can be lined up and taped together VACUUM SW SCRUB SW SOLUTION SW
54. 00 ST Removal and Installation Scrub Brush 1 Turn the key switch off and wait for the Brush Head to rise 2 Disconnect the Battery Pack Connector 3 Loosen the hand wheel nut several turns until the idle cover lowers far enough that the slots clear and allow the cover to be pulled outward If the cover is stuck push down on the hand wheel Slots in Idler Assembly 4 Pull brush out of housing Form Number 56043150 Page 95 service Manual SC750 SC800 SC 750 ST SC800 ST 5 Slide new brush into housing Rotate and lift the end to engage the drive hub flanges with the slots in the end of the brush 6 Position idler pulley in brush end and seat the idler cover flat against the brush head Form Number 56043150 Page 96 service Manual SC750 SC800 SC 750 ST SC800 ST Brush Drive Belt The drive belt is a stretch belt and may appear too short It is not tensioned with a slotted adjustment but instead is stretched on much like a vacuum cleaner belt 1 Remove belt cover 2 Pry the brush drive belt off the drive motor pulley using a screw driver 3 Install the belt on the brush drive pulley first 5 Ifthe belt grooves are not quite in place push on the side of the belt while rotating the pulley until the belt grooves are properly seated in the pulley 6 Reinstall the belt cover Form Number 56043150 Page 97 service Manual 5 750 SC800 SC 750 ST 5 800 ST Brush Head Actuator
55. 1 Motor Total AMP DAW ss hae eb awe eee ee e d 181 Scrub Motor Speed zoom ook occ Ex a 181 ea D E E E Ra tee E 194 Brush Head Actuator Amp 181 226 ees ee be BREE eee lt 191 a x3 eS 191 DOlUFIOD 9 E 4e 5 X 4 E KR e 3 3099 B9 X eee eS 132 F nctional Description gt s aa RE E ox o4 X 4 Wow RE X03 de CE XR X 132 Component Locations 2o xo x ECKE Xo riesi X oxow lt 134 Maintenance and Adjustments uou uos koc wed ow uec Vee DES RSE MEH eR eS ee Re 135 Solution Filter eS UR ORO amp oue 135 TrouplgsHOOP HS uou s uec 4c dex WX Wom eee Ud dk 430 x 3 hee 4 43m 4 202 196 Insufficient Solution uoo oo RO Oo Rom OH E 136 Solution Leaks After Machine Is Shut Off amp amp de wx 6 374 136 Detergent Is Not Being Added to the Solution Machines with optional detergent mixing system 136 Removal and 187 Form Number 56043150 Page iv service Manual 5 750 SC800 SC 750 ST SC800 ST DOLOR VOIE peas eee 187
56. 1 52 017 BRN 18 85 85 SE wi 12 1075 BLK 12 i ME A ERE _ x72 GSG GG GO 022 YEL BRN 18 021 BRN 18 e 8 029 BRN 18 023 BRN 18 VALVE SOLENOID TRACTION 2 028 BRN 1 F 2 K1 h DECK ACTUATOR X9 S4 59 stb 1 35 gt HH 7 1 POT 100K OHM X32 AT X31 30 024 WHT 12 NO CONNECTION K2 J7 HH J4 1 THROTTLE WIPER X53 m amp 1 2 BRUSH J4 2THROTTLE HIGH REF coss wine E X14 al g x yet Al CONTROL BOARD 036 BLU 18 052 BLK 10 _ X80 8 a 8 S amp X27 mol X64 s 2 93 038 WHT RED 18 3 4 5 KEY SW IN v vv X25 9 26 BINE 11 125255252 2228 028 BRN 18 me amp 3231 115 28 5 5 3 3 31 31 31 3 31 31 3 1195 5 4 035 WHT 10 PG DRIVES SPEED CONTROLLER H a E X50 2 CHASSIS BONDING amp MODEL 124 70 WHT WHT OPERATOR INTERFACE 2 R4 1 8 CONNECTION 50 X8 2 e 2 X7 i J4 8 THROTTLE LOW REF RT BRUSH _ 8 z K3 i 4i gt B3 J4 9 SPEED LMT VIPER 8 n _1X56 X24 58 5 aT 24 10 STATUS DUT 1 71 GRN 10 X54 X4 X23 z E i 5 ii ie J4 11 AUX3 DUT X37 8 X22 i g 8 8 88 32 J4 12
57. 2 AUXI DU 4 7 SW TRACTION 5 8 Je 3 52 SCRUB DEC ACT POS 0 WHT BLU BLU J4 1 THROTTLE WIPER RETRACTED POS 0 SW SW TRACTION MOTOR WHEEL DRIVE BLK WHT J4 2 MI SW SOLUTION SOLUTION INC act pos 1 ac PT THROTTLE HIGH REF RET POT SPD LMT GRA 23 GRN 9 BRN BEN J49 SPEED LIMIT WIPER k 5 4 SOLUTION DEC act pus 2 NC 100K RES POS 2 SW COMM R3 ORG BLK J5 1 y WHT BLK 4 8 THROTTLE Low REF RES WHT BLU R4 4 75K BRN 85 186 GRA RED GAC RENTRER CONTACTOR VACUUM K2 GRY ORC_J3 13 BRUSH contactor CONTACTOR BRUSH g 13 2 BLK BLK P4 BRUSH MOTOR sENsE Ue 10 71 086 H GRA BRN 33 11 ounn VACUUM MOTOR sense 52 9 YEL RED VALVE SOLENOID BLK OPTIONAL gt RED x m WHT BRN 5 5 BLK CONTACTOR VACUUM 3 4 21 2 A MOTOR VAC WHT NC K2 RED WHT EBAN ak CONTACTOR BRUSH LS MOTOR LEFT BRUSH POLARITY DISC BRUSHES EON MOTOR RIGHT BRUSH YEL ORG WHT e SE BLK MOTOR LEFT BRUSH POLARITY CYLINDRICAL BRUSHES DCN MOTOR RIGHT BRUSH NOTES WHEN ON BOARD CHARGER IS USED REMOVE BRN WIRE FROM KEY SW CONNECT BRN WIRE FROM BATTERY CHARGER amp REPLACE WITH WHT BRN WIRE FROM CHARGER ALSO DISCONNECT YEL BRN WIRE AT KEY SWITCH FROM BRN WIRE amp CONNECT TO YEL WIRE Form Number 56043150 Page 65 service Manual 5 750 SC800 SC
58. 3 959 9 80 Recovery System 81 Functional Description 81 Component gt ssr sa 82 Troubleshooting 222 2 554 NA oed A909 Pe kd 83 Vacuum Motor Does Not Turn On Scrub function works 2 83 Insufficient Water Pickup 4 m ox om ooh X Ao ow lt 83 Removal and Installation ow RES UB 89 50 85 Vacuum 4 HEURE wo E RAP S S ee NUES 87 MOLO x aub ox RR RES ee EX 9 ees 87 Vacuum Feror mance x sa s sse rmes ketaka bee tee CRORES EEE EER 87 Vacuum Motor Amp amp ey X x cde X oue Seed wwe 87 2 2 ee 87 Scrub System Cylindrical 88 Purnctonal x o o Rom oe Bae a a e 9 4 88 Component bocablODB a0 ane uomo GE GE ode oe cb EUR XR RO dE Gh EG 91 s xx oodd ceo xo R ox 3x k Row x X4 4 Sex BEEBE o a
59. 5 X16 CB ND CONNECTION X66 010 BRN 18 ii e 199013 WELDING RED 1 r bo X11 011 WHT BLU 18 38 1 8 a M4 x17 se X18 06 vr tg X51 X52 17 BRN 18 BLK 12 X48 014 RED 16 ii X49 DEA SUB 2 X72 R 022 1 i X 2 023 BRN 18 n 8 204 K1 VAC 028 BRN er DECK ACTUATOR x9 82 5 X29 esl les X30 E e 026 BRN 18 35 BOREL 2 5 X315 024 WHT 10 4 1 THROTTLE WIPER gt X53 12324558 x74_BRUSH J4 2 THROTTLE HIGH REF Deck x71 J4 X14 i i CHASSIS BONDING X28 63 i CONTROL BOARD me J4 3 AUX2 DUT 052 BLK 1 322333 _ X80 X64 X27 3T WHT 18 S77 aes J3 ta 038 WHT RED 18 34 5 KEY SV N 028 BRN 18 xim A2 j 2 X50 X 5 BONDING 039 BLK 18 MODEL 124 70 8 SPEED LIMIT THROTTLE 5 i X7 EU DAR 18 Pre J4 8 THROTTLE LOW REF lt 7 r 042 WHT BLK 183 4 BRUSH REMOVE 8 VRZ 043 PINK 182222 J4 9 SPEED LMT WIPER 15 yos A Ls d 054 GRA 18 2 J4 10 STATUS DUT j 071 GRN 10 178 8 5 EE 5 g 11 Me 5 J4 11 AUX3 ss TEE z TIE s o 88 7 Mile X37 THU a Lal X22 i 8 8 8 s 28 8 8 J4 12 REV SW IN NOT USED WHEEL T pam OPTIONAL 5 X21 1 14 13 OV NUT USED
60. 6043150 Page 118 service Manual 5 750 SC800 SC 750 ST SC800 ST Component Locations Brush Head Deck Brush Motor Gas Spring Brush Head Actuator Brush Contactor K2 Form Number 56043150 Brush Head Deck Brush Head Actuator K2 LU Electrical Panel co Page 119 service Manual 5 750 SC800 SC 750 ST SC800 ST Troubleshooting Scrub Motors Do Not Turn On Possible Causes e Brush contactor o Open or shorted winding Burned contacts e Wiring e Main Machine Controller Not energizing the brush contactor Drive Motor Controller Not providing machine moving signa Scrub Deck Will Not Raise or Lower Possible Causes e Mechanical binding for the actuator linkage e Brush Head Actuator Check both the motor and the position switches Only one position switch should be open at a time and it should open at the correct position o Actuator Motor Unplug the actuator connector and momentarily supply fused 24v power and ground to two motor terminals to see if the motor will operate Machine harness wire color Pink wire and Gray wire Reverse the polarity to drive it in both directions If the motor will not drive in both directions replace the actuator If it does drive in both directions proceed to check the position switches o Position Switches Access the Main Machine Controller and unplug the electrical connectors Check the retracted position switch Pu
61. 750 ST SC800 ST RED RED xil BLK FUSE 150 A BATTERY 24 VDC RED S PE ORG CIRCUIT BREAKER 30 AMP OPTIONAL 2 ON BOARD BATTERY CHARGER BLK Bt S P E MODEL HFe UIe4VesA B INTERLOCK IN INTERLOCK SERIAL COMM 26 1 J6 2 26 3 WHT BLU SW SPST KEY WHIZ BRN E BRN 53 RED YEL a s BRN CIRCUIT BREAKER 10 AMP YEL BRN 23 14 KEY SWITCH INTERLOCK 224 2004 we 4 1 5 WHT RED status 3 7 WHT ORG Al SW J9 7 4 VAC CONTROL BOARD rev 375 WHT BLK 57 ORG BRN U Mi ACTUATOR MOTOR 2 1 M2 JS 6 vac RED BRUSH ACT 15 10 BRUSH HEAD ACTUATOR SW SCRUB SCRUB INC joes BRN 58 ORGZYEL B J9 98 SCRUB DEC Kew Bug umm WHT 52 RETRACTED POS 0 SW SW SOLUTION J572 SOLUTION I
62. 8 028 18 027 BRN 18 026 BRN 18 1 CONTROL BOARD 1 23 4 5 6 7 8 9 v J2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 CO oo 2790 MAAK CHASSIS BONDING OPERATOR INTERFACE Pm 056 RED YEL 18 057 BLU GRA 18 045 PINK 18 046 GRA 18 058 BLK 18 068 GRN YEL 16 Se eK ag oe S 1 062 YEL RED 18 Form Number 56043150 Page 70 service Manual 5 750 SC800 SC 750 ST 50800 ST 001 RED 10 002 BLK 10 ON BOARD BATTERY CHARGER OPTIONAL 2 S P E MODEL HF2 U124V25A INTERLOCK 1N INTERLDCK OUT SERIAL COMM EE M5 VAC 6 010 BRN 18 28 8 ZER 011 WHT BLU 18 X60 m omer gt lt VALVE SOLENOID J4 1 THROTTLE WIPER J4 2THROTTLE HIGH REF J4 3 AUXe OUT X1 4 052 BLK 10 J4 5 KEY SW IN Ae PG DRIVES SPEED CONTROLLER MODEL 124 70 J4 8 THROTTLE LOW REF J4 9 SPEED LMT WIPER J4 10 STATUS DUT X13 071 GRN 10 J4 11 AUX3 BUT M1 J4 12 REV SW IN NOT USED WHEEL 12052139 J4 13 USED J5 man X12 2 J5 2 AUX1 BUT 073 GRA 10 5 TRANSAXLE 1 075 GRN YEL 16 Form Number 56043150 gt Ol 58 1 024 10 24 025 BLK 12 034 GRA BRN 18 DECK AGLUAL OPTIONAL CHEM PUMF X8 057 BLU GRA 18 056 RED YEL 18 Page 71 service Manual 5 750 SC800 SC 750 ST SC80
63. 8 Usea small amount of Loctite Threadlocker blue 243 or equivalent on all fasteners 9 Apply Loctite Anti seize 90101A to the bore of the eccentric before installing eccentric on brush motor shaft Drive Motor Bearing and Eccentric pr 224 1 Remove the brush head brush motor according to the vious sections 2 Press the eccentric out of the bearing inner race using an arbor press 3 Remove the bearing retainer by removing the three fasteners 4 Press the bearing out of the driver motor using an arbor press Installation 1 Apply Loctite 609 retaining compound to the bearing bore in the driver motor and to the surface of the inner bearing race Form Number 56043150 Page 124 service Manual 5 750 SC800 SC 750 ST 5 800 ST 2 Press the bearing into the driver motor 3 Install the bearing retainer 4 Press the eccentric into the bearing 5 Install a new gasket on the driver motor with the adhesive side toward the driver motor 6 Apply Loctite Anti seize 90101A to the bore of the eccentric Motor Plate and Isolators Removal 1 Remove the brush head from the machine 2 Remove the brush motor 3 Remove the retaining bolts large washers and sleeves Form Number 56043150 Page 125 service Manual SC750 SC800 SC 750 ST SC800 ST 5 Inspect the splash shield and replace if damaged 6 Flip the scrub head upright and remove each of the isolators from the
64. Advance 5 750 5 750 ST SC800 5 800 ST Nilfisk 5 800 Service Manual Advance Models 56112000 SC750 26D 56112004 SC750 28D 56112006 SC750 28C 56112012 SC750 ST 26D 56112013 SC750 ST 28C 56112016 SC800 28D 56112018 SC800 28C 56112024 SC800 32C 56112028 SC800 34D 56112032 SC800 ST 34D 56112780 SC70 28R Nilfisk Models 56112034 SC800 71 56112035 SC800 86 56112036 SC800 71C Nilfisk Advance 11 10 Revised 06 12 Form Number 56043150 service Manual 5 750 SC800 SC 750 ST 50800 ST Contents General Information sasse wow ow 9 9 ada ded os XL 9 XO ER WDR HERES 6 Service Manual Purpose and 6 Other Reference Manuals 7 __ _______ _ __ _ __ __ _ 7 Transporting the Machine se e s es oe Soe ae 2 77 T1 1 7 Cautions and Warnings nuu ox ow X X04 wo Rod 5 KEE ERED 7 7 General Safety Instructions soe sooo ox XE Rx 4 8 General Machine Description 9 Nameplate xm Pom Renere esde 3 9 Know Your Machine 1448426466448 0 RUE E ESAE EUROS E EH 10 Control
65. BRN JS e EEJ LMT VIBER BRUSH pi gt o ACTUATOR BRN Whe WHT J4 2 ngnrncE HIGH REF GRN M AN p p 2 2 POT SPEED LMT FAST C OPTIONAL 3 RED YEL CHEMICAL PUMP n ud li QR ACT POS 0 aoe WHT 52 BLU BLU sentir WIPER RETRACTED POS 0 SW POT THROTTLE MOTOR WHEEL DRIVE BLU GRA 3 SLOW 6 5 3 J2 11 YEL 51 ACT PUS 1 BLK J4 8 THROTTLE LOW REF oe 45 2 QUT GRA 50 act pus 2 em GRN wc 5 BATT CHGR D BRN 85 186 GRA BLK J3 3 BRUSH REMOVE CONTACTOR CDMM R3 Pos 2 su LASER MODULE CONTACTOR BRUSH REMOVE BRN WHT fot ___ OPTIONAL gt B WHT BLU BRN 857 186 GRA RED J3 18 CONTACTOR CONTACTOR VACUUM 34 13 voLTs out K2 J4 12 REV SWITCH IN BRN afle GRY ORG _J3 13 contactor CONTACTOR BRUSH g 33 2 BLK BLK BRUSH MOTOR SENSE 2 10 YEL ORG BRN Alp GRA BRN 33 1 SOLUTION VACUUM MOTOR SENSE 20279 YEL RED BLK VALVE SOLENOID OPTIONAL gt BRN 4 HOUR METER 3 4 RED 30 87 WHT M5 wWN m VACUUM BLK 21 2 A MOTOR VAC K3 WHT 30 87 BLU K2 CONTACTOR BRUSH REMOVE n WHT BAN BIK CONTACTOR BRUSH MOTOR LEFT BRUSH POLARITY DISC BRUSHES MOTOR RIGHT BRUSH YEL ORG WHT rw BLK MOTOR LEFT BRUSH POLARITY CYLINDRICAL BRUSHES MOTOR RIGHT BRUSH WHT
66. Full automatic shutoff feature Enable means that the automatic shutoff feature is turned on disable means that the automatic shutoff feature is turned off To check or change the setting 1 While pressing and holding the vacuum and scrub switches backward and the solution switch forward turn the key switch on 2 Wait about 3 seconds until all of the LEDs light up and then go off Release the switches The Heavy Scrub Pressure Indicator will remain on and the Fault Indicator will be flashing a numeric value that repre sents the current setting To change the setting press the solution switch forward to increase the value or backwards to decrease the value To save the setting press the scrub switch forward All LEDs will turn on then turn off the key switch e 1 blink Enabled e 2 blinks Disabled Form Number 56043150 Page 31 service Manual 5 750 SC800 SC 750 ST 5 800 ST Restore Factory Defaults This function is used to reset all settings to factory default values If this is done the next time the key is turned on it will act as though a new controller has been installed and force you to set the mandatory program options before the machine will operate normally To check or change the setting 1 While pressing and holding the vacuum switch forward and scrub and solution switches backward turn the key switch on 2 Wait about 3 seconds until all of the LEDs light up and then go off Release the sw
67. L It is possible to enable or disable the Recovery Tank Full automatic shutoff feature Enable means that the automatic shutoff feature is turned on The system will shut off the vacuum motor if it senses the tank is full Disable means that the automatic shutoff feature is turned off The system will not automatically shut off the vacuum motor if it senses the tank is full e ENABLED DISABLED To change the setting 1 Scroll through the menu using the Solution Increase and Decrease switches until you get to the desired value 2 Tosave and go back to the main menu press the scrub ON OFF switch Form Number 56043150 Page 36 service Manual 5 750 SC800 SC 750 ST 5 800 ST CHEMICAL RATE BIAS This function allows a fine tuning of the detergent ratio e NONE 10 MORE CHEMICAL 10 LESS CHEMICAL To change the setting 1 Scroll through the menu using the Solution Increase and Decrease switches until you get to the desired value 2 save and go back to the main menu press the scrub ON OFF switch RESTORE DEFAULTS This function is used to reset all settings to factory default values If this is done the next time the key is turned on it will act as though a new controller has been installed and force you to set the mandatory program options before the machine will operate normally e NO e YES To change the setting 1 Scroll through the menu using the Solution Increase and Decrease switches until you get to
68. NC act pos y LESE YEL _ 59 ORG BLU MIDDLE gt POS 1 SW sh ORG GRY J5 4 SOLUTION DEC pos s LORN BATT CHGR RE Pos 2 sw COMM R3 ORG BLK 1 EXTENDED 3 9K WHT BLU ki BRN 85 86 GRA RED_J3 12 VACUUM CONTACTOR p 1 8 ZLK CONTACTOR VACUUM p 42 1 BIK 42 7 BLIK K2 BRN GRY ORG _J3 13 BRUSH CONTACTOR B Je 8 BIK CONTACTOR BRUSH g 33 2 BRUSH MOTOR SENSE 2 10 YEL ORG 1 BRN GRA BRN SOLUTION VACUUM MOTOR sENsE 2 9 YEL RED VALVE SOLENOID K1 BRN W RED 30 87 WHT MS MN 4 CONTACTOR VACUUM 21 9 MOTOR VAC WHT K2 M3 RED WHT BLK CONTACTOR BRUSH MOTOR LEFT BRUSH POLARITY DISC BRUSHES MOTOR RIGHT BRUSH YEL ORG WHT BLK MOTOR LEFT BRUSH POLARITY CYLINDRICAL BRUSHES ez WHEN ON_BOARD CHARGER IS USED MOTOR RIGHT BRUSH MOVE BRN WIRE FR M KEY SW CONNECT BRN WIRE FROM BATTERY CHARGER amp REPLACE WITH WHT BRN WIRE FROM CHARGER BRN WIRE amp CONNECT Form Number 56043150 ALSO DISCONNECT YEL BRN WIRE AT KEY SWITCH FROM Page 66 service Manual 5 750 SC800 SC 750 ST 50800 ST Apa RP
69. Panel SC750 and SC800 Membrane Switch Control Panel 10 Control Panel SC750 ST and SC800 ST Toggle Switch Control ld Machine Specifications 5C750 5 7505 7 15 Machine Specifications 56800 and SC800 5 7 16 Machine Maintenance 17 9 9 4 BONOS x x3 18 Chassis a x93 kee ee 9 0X 19 Functional Description s e s e 19 Control syste sso x x eB 9x REESE RRC RUE RE X 30 EO Eo d 20 F nctional Description e ss gt 55 gt 5355 y RO 4 RUE 20 Component Locations o eooo e e a 21 deee oiae aaa e nai 22 COURS 25565 a bene 25 Coac Lables PPP 22 Service Test Mode uu s woo moo Ea 26 Programming Options SC750 ST and 5 800 ST Models control panel with rocker switches 29 Programming Options SC750 SC amp 00 models Control Panel with membrane switches 38 Removal and Installation s 64 a sa 6 ue 09 x3 x 309 3 py 0 pues RES HOES GS GIN eod o Rom ow Eoo S 38 Main Machine Controller SC750 ST 5 800 ST
70. SC 750 ST SC800 ST Maintenance and Adjustments Adjusting Squeegee Tilt The tilt of the squeegee causes the rear blade to rise up in the center or on the ends depending on which direction the tilt is changed 1 Park the machine flat even surface and lower the squeegee 2 While moving the machine forward slowly turn the Squeegee Tilt Adjustment Knob until the rear squeegee blade flares evenly across the entire width of the squeegee Troubleshooting Leaving Streaks on the Floor Possible Causes e Debris between squeegee blade and floor e Squeegee blade edges are torn or worn e Incorrect squeegee tilt Broken squeegee springs e Bent squeegee support Removal and Installation Squeegee Tool 1 Remove vacuum hose from tool 2 Loosen both wing nuts 3 Remove squeegee tool 4 Reassemble in reverse order Note Over tightening the wing nuts can lead to damaging the squeegee tool by Form Number 56043150 Page 140 service Manual SC750 SC800 SC 750 ST SC800 ST defeating the breakaway feature Squeegee Support 1 Remove squeegee tool 2 Remove squeegee lift cable from support 3 Service Tip The force of the springs against the pivot bolt causes it to tip backwards and makes it difficult to get the assembly removed and back into place Neutralize the spring force by lifting the support up a bit against the spring tension and tie it up with a wire See photo 4 Remove the lower pivot mounting n
71. Scroll through the menu using the Solution Increase and Decrease switches until you get to the desired value 2 Tosave and go back to the main menu press the scrub ON OFF switch CHARGER SELECTION This function is used to inform the Main Machine Controller whether or not the machine is equipped with the optional on board charger If it is it is also used to inform the controller of what kind of batteries the machine is equipped with The Main Machine Controller will request a specific charging profile from the battery charger to match the batteries e Use when not equipped with on board battery charger e WET 25 Use with 242 AH WET Batteries 56206079 or 310 AH WET Batteries 56391391 AGM DISCOVER 25A Use with 312 AH AGM Batteries 56315959 e 25A GEL AGM 25A e WET 15A GEL AGM 15A To change the setting 1 Scroll through the menu using the Solution Increase and Decrease switches until you get to the desired value 2 Tosave and go back to the main menu press the scrub ON OFF switch LOW VOLT CUTOUT The purpose of the low battery voltage cutout function is to help prolong battery life The scrub deck will be raised and the brush motors vacuum motor and solution solenoid valve will turn OFF automatically and cease to function when the batteries discharge to the selected cutout level The cutout level is adjustable between two settings The standard setting wet cell lead acid is 20 55 volts and alternate
72. T SC800 ST Component Locations e Solution tank e Shut off valve Ball Valve e Solution filter e Solution solenoid valve e Detergent pump e Detergent tank e Solution drain hose filter Shut off valve Detergent Pump Solution Solenoid Valve Form Number 56043150 Page 134 service Manual SC750 SC800 SC 750 ST SC800 ST Maintenance and Adjustments Solution Filter Cleaning 1 Work near a floor drain for convenient clean up if possible Turn the key switch off Close the shut off valve The valve is closed when the lever is NOT in line with the hose Unscrew the solution filter cover Remove and clean the screen Reassemble in reverse order Note Over tightening the cover will cause it to crack Open the shut off valve Form Number 56043150 Page 135 service Manual 5 750 SC800 SC 750 ST 5 800 ST Troubleshooting Insufficient Solution Flow Possible Causes e Restricted solution filter e Debris sludge in solution tank clogging fitting to shut off valve e Pinched hose e Restricted solution valve Solution Leaks After Machine Is Shut Off Possible Causes e Solution valve not sealing Worn or debris holding it open e Hose or fitting leak before solution valve Detergent Is Not Being Added to the Solution Machines with optional detergent mixing system Possible Causes e Detergent tank empty e Detergent hose blocked or leaking e Detergent pump e Wir
73. Turn Key Switch off to exit mode Now that you are in service test mode you can request that the controller operate the various outputs and verify certain inputs via the LCD display If any faults occur during testing they will be displayed as well Output Tests Brush Deck Lift Actuator Press the Scrub Increase Switch to move the actuator downward to the next position Watch for the actuator to move Press the Scrub Decrease Switch to move the actuator up one position The LCD display for DECK will show On when the controller is trying to move the actuator and Off when it is not Machines with disc scrub decks have three positions while cylindrical decks have only two Note If the switch inputs are not reporting cor rect information the controller will not understand the current actuator position and will not attempt to move the actua tor Brush Remove Contactor Relay Press the Brush Remove Switch to energize the brush remove relay During this test the Brush Motor Contactor will be de energized Listen closely for the relay to click It is a soft click It won t be heard in a noisy room Press the switch again to de energize the relay The LCD display for BREM will show On when the controller is trying to energize the relay and Off when it is not Form Number 56043150 Page 27 service Manual 5 750 SC800 SC 750 ST 5 800 ST Solution Solenoid Press the Solution Switch to cycle the solution solenoid on an
74. X14 052 BLK 10 x1 ON GRN 10 M 1 WHEEL xus ch X12 013 GRA 10 CHASSIS BONDING TRANSAXLE 075 GRN YEL 16 CHASSIS BONDING X80 034 GRA BRN 18 X54 050 BRN 055 GRN YEL 16 046 GRA 18 047 WHT 18 048 YEL 18 049 GRN 18 NO CONNECTION X81 X82 i x 051 WHT 10 057 BLU GRA 18 056 RED YEL 18 063 YEL ORN 18 007 BLK 10 RT BRUSH 21X00 us AN 070 WELDING BLK 6 Form Number 56043150 032 WHT 18 ND CONNECTION Page 76 service Manual SC750 SC800 SC 750 ST SC800 ST Options and Accessories Battery Fill Indicator The Battery Fill Indicator provides a quick visual indication of when one of the battery cells is low and needs water added It is installed in place of one of the battery fill caps The wire lead goes to the battery negative terminal When the level is Okay the green LED is lit Battery Watering Kit The battery watering kit provides a convenient way to add water from a jug into all battery cells at once Each battery has a manifold that replaces the fill caps The manifolds are connected with rubber hoses to one another and to a fill port A separate filler tool is connected to the fill port on one end and the other end goes into a container of distilled water Squeezing and releasing the bulb pumps the water into all of th
75. YEL BRN ERN CIRCUIT BREAKER 10 AMP YEL BRN 33 41 key swITCH CHRGR INTERLOCK 2224 BRN WHT RED JB gy 36 WHT RED YEL J3 8 p WHT ORG status 23 7 _ WHT ORG 13 5 WHT BLK WHT BLK CONTROL BOARD ay ACTUATOR MOTOR M2 BRUSH J1 4 PINK 20 BRUSH 22 5 GRA BRUSH HEAD ACTUATOR Je e BRN M6 _ OPTIONAL gt ON RED YEL CHEMICAL PUMP mw ACT PDS 0 HET WHT 52 RETRACTED POS 0 SW BLU GRA J1 3 CHEMICAL PUMP 7 Act pas pec YEL we MIDDLE Bos 1 50 K3 act Pos e p GRN BATT CHGR gt BRN 85 86 GRA BLK 13 3 BRUSH REMOVE CONTACTOR COMM R3 2 Sw EXTENDED 3 9K CONTACTOR BRUSH REMOVE BRN WHT BLU K BRN 85 186 GRAS RED J3 48 p 1 8 BLK CONTACTOR VACUUM 21 32 7 BLK K2 BRN GRY ORG 3 13 BRUSH CONTACTOR p Je 8 BIK CONTACTOR BRUSH p 43 2 BIK BLK cb BRUSH MOTOR SENSE 2 10 YEL ORG BLK BRN GRA BRN 13 SOLUTION VACUUM MOTOR sense 2 9 YEL RED VALVE SOLENOID BRN RED 30 87 WHT CONTACTOR VACUUM BLK 21 2 A MOTOR VAC BLK WHT 30 87 BLU K2 CONTACTOR BRUSH REMOVE RED WHT BLK BLK CONTACTOR BRUSH MOTOR LEFT BRUSH POLARITY DISC BRUSHES MN MOTOR RIGHT BRUSH YEL ORG WHT E ue BLK MOTOR LEFT BRUSH POLARITY CYLINDRICAL BRUSHES MAN MOTOR RIGHT BRUSH WHT BNN BIK D MOTOR LEFT BRUSH POLARITY REV2 DECK EGG MOTOR RIGHT BRUSH A
76. adient exceeding that marked on the machine doors and covers to be positioned as indicated in the instruction manual before using the machine General Machine Description The SC SC750 SC800 SC75 ST and SC800 ST machines are battery powered walk behind floor scrubbers designed to clean flat hard surfaces They are powered by a 24 volt battery pack They have one controller that operates the scrub and vacuum functions and another that operates the drive system They can be equipped with either a Disc scrub deck or a Cylindrical scrub deck Nameplate The nameplate contains important identification information which will be needed when ordering parts Model Name Part No Part number of the machine which is often referred to as the Model Number and Serial Number E LE m Nameplate Nilfisk Advance Inc Plymouth MN USA www nilfisk advance com Form Number 56043150 Page 9 service Manual SC750 SC800 SC 750 ST SC800 ST Know Your Machine Control Panel SC750 and SC800 Membrane Switch Control Panel These machines use a control panel with an LCD display in the center See the following sections for switch identification LCD Display explanations and Indicator Light explanations Solution Increase Display Panel Scrub Pressure Switch M Increase Switch Brush Remove ER Switch Disc Decks Only I cte veg o Vacuum Wand Switch Scrub Pressure Decre
77. age The LCD will display the battery voltage seen by the Main Machine Controller when in the Service test mode Speed Control Forward Reverse Signal AND Reverse Signal The Main Machine controller interprets these two signals that it receives from the Drive Motor Controller and displays the information on the LCD e OFF Neutral e FWD Forward e REV Reverse Move the drive paddle in all three directions If all 3 values are displayed correctly both of these inputs are working correctly Form Number 56043150 Page 28 service Manual 5 750 SC800 SC 750 ST 50800 ST Programming Options 5 750 ST and SC800 ST Models control panel with rocker switches Main Machine Controller special program options allow the service repairperson to match the control board to the specific model equipment and to user preferences They also allow adjustments to some machine functions and provide a way to see the controller s revision level On ST models each program option mode is accessed by pressing a specific configuration of buttons while turning the key on Mandatory Program Options These options are used to inform the Main Machine Controller how the machine is equipped They must be set any time the Main Machine Controller is replaced and they must be set correctly for the machine to operate as it should Scrub Deck Type There 3 scrub deck options This function configures the control unit current settings flow rate
78. ain Machine Controller SC750 and SC800 Models Later build Note Electronic devices like the Main Machine Controller are sensitive to Electrostatic Discharge ESD Before handling the controller touch a metal bench or shelf to discharge any electrical charge that may have built up in your body Do not walk around with a controller in your hands Summary Remove the electrical panel cover as an assembly and place on a bench Then remove the main machine con troller from the cover Do not remove the control switch interface panel before the cover is removed from the machine 1 Completely drain solution tank This is important for the solution level sensor to work properly upon reassembly 2 Turn off and remove key 3 Remove top two handle bolts and loosen the lower two Rotate Handle Assembly down Form Number 56043150 Page 44 service Manual SC750 SC800 SC 750 ST SC800 ST 5 Remove circuit breaker plate attaching screws 5 Remove E Ar 1 rr nee Se en Pm cete e Qoo ree ee 6 Remove nut securing key switch 8 Loosen electrical panel cover lower mounting screws _ Loosen TPE Form Number 56043150 Page 45 service Manual 5 750 SC800 SC 750 ST 50800 ST 9 Tip cover away from machine a Remove the screw securing the ground wire to the back of the control switch interface panel b Disconnect the
79. and recovery tanks 2 Remove the squeegee tool 3 Remove the batteries 4 Remove one drive wheel and remove the transaxle mounting bolts behind it Transaxle Mounting Bolts 5 With the help of an assistant lay the machine on its side Lay it on the side that has the wheel off and be sure to protect the side from damage Form Number 56043150 Page 159 service Manual 5 750 SC800 SC 750 ST 5 800 ST 6 Remove the other drive wheel and the transaxle mounting bolts behind it 7 Disconnect the transaxle motor electrical connector 8 Make a note of how the transaxle is oriented in the frame before removing it so that it is reassembled correctly 9 Remove the transaxle by sliding it out of the frame slots 10 Reassemble in reverse order Transaxle Drive Motor Carbon Brushes 1 Remove transaxle 2 Remove round black plastic brush cap 3 Remove carbon brush and spring Remove Brush and Spring Form Number 56043150 Page 160 service Manual 5 750 SC800 SC 750 ST 5 800 ST 4 Install brush and spring Install and tighten cap with a screwdriver ba Reinstall Brush Cap Install Brush and Spring 5 Repeat steps for all 4 carbon brushes Specifications Drive Wheels Diameter 10 in 25 4 cm Width 3 in 7 62 cm Type Material Polyurethane Foam molded Drive Motor 4HP 298 watts Max Transport Speed Fwd 5 75 km h 3 57 mph Rev 4 36 km h 2 71 mph Drive Mo
80. and rotate handle down Disconnect handle electrical connector Remove the access plate Disconnect 3 electrical connectors Make sure you carefully record the wire colors and their positions so that you will be able to reconnect them correctly Remove potentiometer Reassemble in reverse order Speed Limit Potentiometer Non ST models 1 2 Remove upper handle bolts Loosen lower handle bolts and rotate handle down From the back side of the paddle remove the 4 screws securing the front cover Partially remove the front cover Disconnect the wiring from the speed limit poten tiometer Make sure you carefully record the wire colors and their positions so that you will be able to reconnect them correctly Remove front cover Remove the potentiometer knob and mounting nut Reassemble in reverse order Form Number 56043150 Remove 1 Access Plate 1 Page 152 service Manual SC750 SC800 SC 750 ST SC800 ST Palm Button Switches ST models 7 Remove two switch mounting screws Remove upper handle bolts Loosen lower handle bolts and rotate handle down Remove access plate Disconnect wiring Make sure you carefully record the wire colors and their positions so that you will be able to reconnect them correctly Remove switch and wiring a Tip To make it easier to install a new switch use a spare piece of wire attached to the wires of the old switch when you pull it out Attach th
81. ase Switch Key Switch Main Power Burst of Power Switch Solution ON OFF Switch Solution Decrease Switch Detergent ON OFF Switch Switch Identification e Key Switch Main Power Turns ON the power to the control panel O is OFF and I is ON Solution ON OFF Switch Starts or stops the flow of cleaning solution to the floor Solution Increase Switch Increases the amount of cleaning solution flow Solution Decrease Switch Reduces the amount of cleaning solution flow Detergent ON OFF Switch Starts or stops the flow of detergent on models with the EcoFlex detergent mixing system Display Panel Provides additional machine operation information Scrub ON OFF Switch Raises and lowers the scrub head assembly Enables disables the vacuum motor solu tion flow and the scrub motors Form Number 56043150 Page 10 service Manual 5 750 SC800 SC 750 ST SC800 ST e Scrub Pressure Increase Switch Extends the scrub head actuator to apply additional scrubbing pressure on the floor Disc models only e Scrub Pressure Decrease Switch Retracts the scrub head actuator to the normal scrub pressure position Disc models only e Burst of Power Switch Temporarily provides additional scrubbing power For use with optional detergent mix ing system Brush Remove Switch Disc Decks Only Initiates a sequence to run and suddenly stop
82. at tery positive and negative Connect them to the two actuator motor wires at the Main Machine Controller connector Pink wire at connector J1 pin 4 and Gray wire at connec tor J1 pin 5 Change polarity to change direction Immediately remove jumper wires at the end of motor travel e Monitor the ohmmeter It should show an open circuit no continuity only when the actuator is in the retracted position In all other positions it should show a closed circuit continuity Form Number 56043150 Page 110 service Manual 5 750 SC800 SC 750 ST 50800 ST e Wiring Check the middle position switch Put the black ohmmeter lead on the Brown wire at the J2 connector pin 2 Put the red ohmmeter lead on the Yellow wire at the J2 connector pin 11 Drive the actuator motor all the way up and down using jumper wires powered by bat tery positive and negative Connect them to the two actuator motor wires at the Main Machine Controller connector Pink wire at connector J1 pin 4 and Gray wire at connec tor J1 pin 5 Change polarity to change direction Immediately remove jumper wires at the end of motor travel Monitor the ohmmeter It should show an open circuit no continuity only when the actuator is in the middle position In all other positions it should show a closed circuit continuity Check the extended position switch Put the black ohmmeter lead on the Brown wire at the J2 connector pin 2 Put the red ohmmeter lead on the Green
83. attempted to energize the Brush Contactor but it is not seeing any current flow Senses 20 m Amps for 5 seconds Check for open Contactor winding wiring The Main Machine Controller has attempted to energize the Vacuum Contactor but it is not seeing any current flow if Senses lt 20 m Amps for 5 seconds Check for open Contactor winding wiring The Main Machine Controller has energized the deter gent pump but it is not sensing any current flow Senses lt 30 m Amps for 5 seconds Check for open pump winding wiring The Main Machine Controller has attempted to energize the Brush Remove Contactor but it is not seeing any cur rent flow Senses lt 20 m Amps for 5 seconds Check for open Contactor winding wiring The Main Machine Controller is sensing current flow through the Brush Motor ground circuit when it has not energized the Brush Motor Contactor Senses 4 Amps for 5 seconds and Fault Code 63 is not active Check for welded contacts The Main Machine Controller is sensing current flow through the Vacuum Motor ground circuit when it has not energized the Vacuum Motor Contactor Senses 3 Amps for 5 seconds and Fault Code 64 and 65 are not active Check for welded contacts Page 24 service Manual 5 750 SC800 SC 750 ST 5 800 ST LCD Code Display Definition Solution Solenoid Circuit Stuck On Brush Contactor Coil Circuit Stuck On Vacuum Contactor Coil Circuit Stuck On
84. clear pressure sensor hose from the fitting at the solution tank DO NOT TRY TO DISCON NECT THE HOSE FROM THE CIRCUIT BOARD Do not remove hose Only disconnect hose from control board at solution tank fitting c Unplug main machine controller electrical connectors d Free circuit breakers handle switch connector and key switch from cover assembly Form Number 56043150 Page 46 service Manual SC750 SC800 SC 750 ST SC800 ST 10 Remove the electrical panel cover assembly and place on a work bench a Remove the 5 screws securing the switch panel interface and carefully turn the cover over b Remove 4 screws securing circuit board Main Machine Controller to cover c Remove the control switch interface panel and main machine controller circuit board together through the cover opening 11 If the board is being replaced you will need to use a new pressure sensor tube or transfer the existing tube from the old board Follow the steps below to transfer the tube Form Number 56043150 Page 47 service Manual 5 750 SC800 SC 750 ST 50800 ST a Use a small sharp knife to cut the tube off near the sensor on the board 1 mm from sensor b Make a shallow slit with the knife along the length of the clear tube that is still attached to the sensor port Do not press too hard and avoid cutting into the sensor port Make 3 or 4 passes with the knife pressing softly rather than one hard cut See the photos below
85. computer it can be enlarged to be legible while retaining the convenience of a single page The following pages are the same diagram enlarged on two pages so that they are legible when printed A BAT RED RED BLK FUSE 150 A BATTERY 24 VDC RED ORG CIRCUIT BREAKER 30 AMP OPTIONAL gt A3 ON BOARD BATTERY CHARGER BLK t B OSPE MODEL HF2 U124V254 B 1 INTERLOCK IN INTERLOCK OUT SERIAL COMM J6 1 J6 2 J6 3 WHT BLU SW SPST KEY WHT BRN BRN 82 53 RD tL QOL aa BRN BRN CIRCUIT BREAKER 10 AMP YEL BRN_J3 14 KEY SWITCH INTERLOCK 3 4 uiu 208 KEY SW IN BY JS y 3 6 WHT RED NELLE YEL J3 8 5 BLK status 8 7 WHT ORC 4 10 status M PG DRIVES SPEED CONTROLLER 7 55 7 CONTROL BOARD gey 3 5 xs 124 70 57 ORG BRN i t i ORG RED d c GM GRA ut J9 6 vac OFF BRUSH ACT 122 4 RED w E ONE GRA REV SWITCH IN BRUSH HEAD ACTUATOR SW SCRUB 43 10 SCRUB INC BRN S4 CRN S8 ORG YEL g 2 2 5
86. d Control Potentiometer inside the paddle A separate Speed Limit Potentiometer is rotated to control the maximum speed The drive motor controller has internal voltmeters that are monitoring 2 inputs 1 Drive Paddle Position To know when to move and which direction 2 Speed Limit To know what the maximum speed should be The drive paddle Position potentiometer is fed 5 volts from the controller on one side of its resistive strip The voltage goes through the resistive strip and returns to battery negative inside the controller The wiper inside the potentiom eter will return a voltage back to the controller as a direction request input If the wiper is exactly in the middle as it should be when drive paddle is in the spring loaded position the return voltage will be of the supply voltage 2 5v As the paddle is pushed forward the wiper moves closer to the supply side resulting in an increase in voltage Volt age above 2 5v is interpreted as a forward request The same input is also used for more or less speed As the paddle is pushed farther forward the voltage will increase and it will be interpreted as a request for more speed in the forward di rection When the drive paddle is pulled back the voltage will drop below 2 5v and is interpreted as a reverse request The Speed Limit Potentiometer is fed 5 volts from the controller on one side of its resistive strip The voltage goes through the resistive strip and returns to ba
87. d off Listen for the Solenoid to click on and off Press the switch again to stop cycling the solenoid The LCD display for SOL will show On as long as the test mode is running that is when the controller is trying to cycle the solenoid both on and off The LCD display for SOL will show Off when the test mode is ended Brush Motor Contactor Press the Scrub On Off Switch to energize the brush motor contactor Listen for the contactor to click and look to see if the brushes are rotating Press the switch again to de energize the contactor The LCD display for BR will show On when the controller is trying to energize the contactor and Off when it is not Vacuum Motor Relay Press the Vacuum Wand Switch to energize the Vacuum Motor Relay The vacuum motor should come on Press the switch again to de energize the relay The LCD display for VAC will show On when the controller is trying to energize the relay and Off when it is not Detergent Pump Press the Detergent On Off Switch to cycle the detergent pump on and off Listen for the pump to op erate Press the switch again to stop cycling the pump The LCD display for CP will show On aslong as the test mode is running that is when the controller is trying to cycle the pump both on and off The LCD display for CP will show Off when the test mode is ended Input Tests When in the service test mode the LCD display can be used to validate certain inputs Battery Volt
88. detection checks to facilitate troubleshooting This will not disable the over current protection on any of the systems To check or change the setting 1 While pressing and holding the vacuum and solution switches forward turn the key switch on 2 Wait about 3 seconds until all of the LEDs light up and then go off Release the switches The Medium Solution Flow Indicator will remain on and the Fault Indicator will be flashing a numeric value that repre sents the current setting To change the setting press the solution switch forward to increase the value or backwards to decrease the value To save the setting press the scrub switch forward All LEDs will turn on then turn off the key switch e 1 blink Fault Detection Enabled e 2 blinks Fault Detection Disabled Form Number 56043150 Page 32 service Manual SC750 SC800 SC 750 ST SC800 ST Software Revision Code This function is used to display the software revision The Fault LED blinks a two part code to indicate the revision of the software that is currently programmed into the microcontroller program memory The first part of the code indicates the released revision letter 1 blink revision A 2 blinks revision B etc To check the revision 1 While pressing and holding the vacuum and scrub switches forward turn the key switch on 2 Wait about 3 seconds until all of the LEDs light up and then go off Release the switches The Low Medium and High Solu
89. e batteries simultaneously As each battery cell becomes full a shut off valve closes in its battery cap Once all of the valves are closed the pump bulb will feel hard since it can no longer pump water Fill Port Form Number 56043150 Page 77 service Manual 5 750 SC800 SC 750 ST 5 800 ST Hour Meter The hour meter keeps track of the run time of the scrub motors On board Battery Charger An optional on board battery charger is available It attaches to the bottom of the machine See the Electrical System chapter for more information Battery Charger Wiring for On board Charger When the charger is installed the machine wiring at the Key Switch must be modified for the interlock circuit to func tion properly See the Electrical System chapter for more information To modify the Key Switch Wiring See Instruction Sheet Form No 56090019 1 Move wire 022 YEL BRN from Key Switch pin 1 to Key Switch pin 2 2 Remove wire 017 BRN from the Key Switch and plug it into wire 010 BRN at connector X66 3 Install wire 009 WHT BRN on the Key Switch pin 1 Form Number 56043150 Page 78 service Manual 5 750 SC800 SC 750 ST 5 800 ST Wiring Without Onboard Battery Charger Key switch CB2 vg B 019 2 BRN 017 Drive Motor Controller YEL BRN 022 Main Machine Controller Wiring VVith Onboard Battery Charger X Interlock Relay 4 Battery Charger Key Switch
90. e ignited by any electrical arc spark or flame Do not install any lead acid battery in a sealed container or enclosure Hydrogen gas from overcharging must be allowed to escape When servicing batteries e Remove all jewelry smoke e Wear safety glasses rubber gloves and a rubber apron Work in a well ventilated area e Do not allow tools to touch more than one battery terminal at a time e ALWAYS disconnect the negative ground cable first when replacing batteries to prevent sparks ALWAYS connect the negative cable last when installing batteries AN caution Electrical components in this machine can be severely damaged if the batteries are not installed and connected properly Only Nilfisk Advance a qualified electrician or the battery manufacturer should install batteries 1 Empty the recovery tank and tip it up 2 Turn the key switch off and disconnect the main battery pack connector 3 Remove the battery cables Do allow metal tools to connect between battery cables or posts b Prevent cable ends from touching other cable ends or posts 4 Remove battery 5 Install battery 6 Reconnect battery cables making sure that they are connected properly Refer to the diagram molded into the lower side of the recovery tank Form Number 56043150 Page 60 service Manual 5 750 SC800 SC 750 ST 5 800 ST Battery Charger Optional On board Battery Charger The battery charger is mounted to the bottom o
91. e new switch wires to the spare wire to pull the wiring back through the handle Reassemble in reverse order Reverse Switch ST models 1 2 Remove upper handle bolts Loosen lower handle bolts and rotate handle down Remove access plate From inside the handle area push the reverse switch out of the handle Disconnect wiring and remove Make sure you care fully record the wire colors and their positions so that you will be able to reconnect them correctly Reassemble in reverse order Form Number 56043150 Page 153 service Manual 5 750 SC800 SC 750 ST SC800 ST Handle Wiring Connections ST models Component Wire color Wire Color Harness To Main Machine Controller Component Side side A1 Pin Handle Wiring Speed Pot Harness Wiper Right Traction BRN Switch BLU BLU Left Traction Switch BLU Reverse Switch GRA Reverse Switch PNK Speed Pot Low Ref BLK BLK R4 Speed Pot Hi WHT WHT Right Traction Left Traction Switch Switch WHIT WHT WHT BLK R4 Form Number 56043150 Page 154 service Manual SC750 SC800 SC 750 ST SC800 ST Paddle Position Sensor Non ST models SC750 SC800 Photos are shown working on a bench top but this can be done on the machine 1 Remove top two handle mounting bolts 2 Loosen the bottom two handle mounting bolts and rotate handle down 3 From the back side of th
92. e paddle remove the 4 screws securing the front cover Remove the front cover 4 Disconnect wiring from the potentiometer Make sure you carefully record the wire colors and their positions so that you will be able to reconnect them correctly Form Number 56043150 Page 155 service Manual SC750 SC800 SC 750 ST SC800 ST 5 Remove the cam controller Remove Cam Controller gt 6 Loosen set screw and remove the potentiometer fork 7 Remove the potentiometer mounting nut and washer 8 Install the potentiometer 9 Loosely install the potentiometer fork 10 Install the cam controller inserting the pin end into the fork Form Number 56043150 Page 156 service Manual SC750 SC800 SC 750 ST SC800 ST 11 Adjust the potentiometer position a Measure the resistance between the two outer terminals and write the value down d E J rem qO T T E E LER 2008 RANGE b Hook up your ohmmeter leads between the center terminal and one of the outer terminals Using small slotted screwdriver in the end of the potentiometer shaft rotate the shaft until the value on the ohmmeter is exactly gt of the value written down in step a DC AC TTL BH MESE RANGE IET Temp Hz Tighten the fork set screw 12 Reconnect the wiring 13 Reinstall the paddle cover Reconnect the speed limit potentiometer wiring 14 Rotate the
93. ee ee eaeeavaetre eteeet ase 4 ee 45 4 5 eee ex 104 Brush Disce Remove FeatuTe 4 xx kd Ga Bee X 3 ox b ox amp BRE RES x 107 Component Locations se c s a sa ed eed 9 4 ck Wm eee 109 v Xxx uw 4 9E SS e 94a 110 Serub Motors Do Not s s R OUR Ru EERE XD eh we EG 110 Scrub Deck Will Not Raise OF Lower uus ws bebe eek ede eee Eos x 5 6 x3 4 110 Removal Installation ese eee EER ee 112 eee ee 112 e us URS EUER REGES SXSeu s5 KM REESE WERE 112 Srub Motor CORDON ses s Ra oe idy X wx 35 OX ROB RAISES S 113 Brush Head Actuator s Eb EKER gt a 114 9 xw RW ARX eee eee we ee 953 Ew d eae 115 Scrub Motor AMO DIOW s s ses eH 115 Srub Motor Total Amp Dis se s ewe bebe eee bis nana Pee 115 Scrub Motor Speed s sas sarerea BE 115 ee ect 115 Brush Head Actuator Amp Draw 4 s se eo mox owe mo EEO EHH 6 115 R e v E E E eee EGER EER EG 115 EEE E E E E E
94. eed and by changing polarity to control direction The secondary job is to notify the Main Machine Controller when the machine is moving and which direction it is moving The Main Machine Controller uses this information to start and stop the solution flow and scrub functions To move the machine forward the controller connects terminal M2 to battery negative AND connects terminal M1 to battery positive To regulate the speed the controller pulses the battery positive voltage out to terminal M1 at a fixed frequency called a duty cycle The greater the percentage of on time that the circuit is connected to battery positive the faster the machine will go To move the machine in reverse terminal M1 is connected to ground and terminal M2 is pulsed to battery positive volt age The speed in reverse is intentionally reduced SlowSpeed Medium Speed gt High Speed Short time Longer on time on time 1 200600 1 10 V 20 r 1 10 V 20 The Drive Motor Controller tells the Main Machine Controller when the machine is moving and what direction it is mov ing Two circuits are used for this purpose the FOR REV and the REV circuit Here is how the FOR REV circuit works The Main Machine Controller sends 24 volts out through an internal resistor to the Drive Motor Controller The Drive Motor Controller has an internal switch to battery negative B When the mac
95. er inside the potentiometer will return a voltage back to the controller as a speed request input If the wiper is close to the supply side the voltage will be high 4 6v Maximum speed request If it is close to the battery negative return side the voltage will be low 0 2v Minimum speed request The reverse switch provides the directional request input Here is how it works The Drive Motor Controller sends ap proximately 2 8v through an internal resistor out to the reverse switch An internal voltmeter monitors the voltage When the reverse switch is open 2 8v is seen This is interpreted as a forward direction request When the reverse switch closes it connects the voltage to battery negative through the Drive Motor Controller This drops the voltage from 2 5v to nearly Ov This is interpreted as a reverse direction request Form Number 56043150 Page 144 service Manual 5 750 SC800 SC 750 ST SC800 ST Drive Motor Control Circuit Forward Direction ST Models Drive Motor Controller Drive Motor Ba TLL B 15 R4 m Resistor Reverse T Switch Palm Speed Switches Limit Potentiometer Page 145 Form Number 56043150 service Manual 5 750 SC800 SC 750 ST 5 800 ST Drive Motor Controller Outputs The primary job of the Drive Motor Controller is to operate the electric transaxle drive motor It does this by regulating current flow through the drive motor to control sp
96. ergizing the relay The vacuum motor should come ON Press the Vacuum Switch backward to de energize the relay Form Number 56043150 Page 26 service Manual 5 750 SC800 SC 750 ST 50800 ST Input Tests Speed Control Forward Reverse Signal The yellow Battery LED turns on when in the service test mode whenever the speed controller tells the Main Machine Controller that it is attempting to drive the machine either forward or reverse This is useful when diagnosing a no drive problem If the light comes on when you attempt to drive the machine forward it means that the Drive Controller has seen the request and responded to it Speed Control Reverse Signal The green Battery LED turns on when in the service test mode whenever the speed con troller tells the Main Machine Controller that it is attempting to drive the machine in reverse Service Test Mode C750 and SC 800 Models Control Panel with membrane switches To enter the service test mode Start with the battery charger unplugged and the key off 1 Press and hold the scrub on off switch and vacuum wand switch together 2 While holding both switches turn the main power key switch to the on position 3 Continue to hold both switches about 3 seconds until the display shows Programming Options then release the switches 4 Pressthe solution decrease button until you see SERVICE TEST MODE then press the solution on off switch to enter the Service Test Mode Note
97. ery negative connection to one of the open when energized contacts Since that side of the contactor is open at this time nothing changes but the system is armed and ready Form Number 56043150 Page 107 Step 3 service Manual 5 750 SC800 SC 750 ST 50800 ST Brush Remove Step 2 Key Switch Brush Contactor Motors Main Machine Controller Next the brush motor relay is de energized This removes the battery positive power source from the motor AND instead connects the motor to battery negative through the normally closed contacts The motor stops abruptly when both sides are connected to battery negative It is the abrupt stop that releases the brush lugs from the plate retaining spring After a time out period the Main Machine Controller de energizes the brush remove relay Form Number 56043150 Brush Remove Key Switch energized Brush Brush Contactor Motors De energized Main Machine Controller Page 108 service Manual 5 750 SC800 SC 750 ST 5 800 ST Component Locations e Brush Head Deck e Brush Plate e Brush Motor e Gas Spring e Brush Head Actuator e Brush Contactor e Brush Remove Relay Brush Plate a E Rotation Brush Head Actuator Form Number 56043150 Brush Head Deck Rev A e gt 4 7 L 4 4 pm A 1 4 2 w N 4 gt t b Brush Re
98. ery tank 2 Press the scrub button to lower the brush head a Ifthe actuator does not move slightly raise the brush head with a jack to take tension off of the mount ing hardware 3 Tip the recovery tank up 4 Disconnect electrical connector so the actuator will not move and then turn the key off 5 Remove upper and lower fasteners E d p pua gt Upper F Fastener 6 Remove actuator 7 Reassemble in reverse order 8 Tighten the upper actuator nut and bolt until it is snug and then back off approximately 1 2 turn This joint must be allowed to move freely Form Number 56043150 Page 130 service Manual 5 750 SC800 SC 750 ST 50800 ST Specifications Scrub Motor Amp Draw No Load Approximately 16 19 Amps one motor Note Only run the test for a few seconds Remove the pads before testing no load amp draw as the motor will spin the pad driver around 2 000 RPM and may throw the pad Scrub Motor Total Amp Draw Total amp draw will vary widely based on floor surface solution flow and pad type You may see anywhere from 12 32 Amps both motors when stripping or scrubbing Epoxy floor and red pads normal scrub mode Measured 25 26 Amps Epoxy floor and red pads extreme scrub mode Measured 28 10 Amps Scrub Motor Speed Approximately 2 000 RPM Scrub Force Regular Scrub 70 4 lbs 31 9 kg Extreme Scrub 170 lbs 77 1 kg Brush Head Actuator Amp Draw Upward with
99. et motor transaxle is used to propel the machine in both forward and reverse directions The con trols for forward reverse and speed are different between the ST SC 750 ST SC800 ST and 5 5 750 5 800 Models The SC750 and SC800 models use a drive paddle with an angle sensor potentiometer as an input for forward and reverse with a variable speed signal They also have a separate speed limit potentiometer to control the maximum speed The SC750 ST and SC800 ST models use a combination of two switches There are 2 Palm Drive Buttons anda Reverse Button When either palm drive button is pressed the machine will go forward If the reverse button is pressed while a palm drive button is pressed the machine will move in reverse ST models also have a separate speed control potentiometer It controls the speed of travel On both models the speed in reverse is intentionally less than in forward The Drive Motor Controller varies the amount of voltage it applies to the drive motor to control speed It reverses the polarity to change direction The Drive Motor Controller is capable of informing the Main Machine Controller that it sees a problem but there are no specific drive system codes to retrieve Drive Motor Circuit Description SC750 ST and SC800 ST models Powering up the Drive Motor Controller The controller is connected directly to battery positive B and battery negative B These supply the power that the control
100. f the frame with 4 bolts that are screwed into threaded holes 1 Cut tie straps securing AC power cable Remove 4 2 Cut tie straps securing electrical connectors mounting bolts two on each end of charger 3 Disconnect electrical connectors 4 Remove 4 battery charger mounting bolts 5 Remove charger thread AC power cable through opening 6 Reassemble in the reverse order Tie wiring in same loca tions using new tie straps Specifications Low Voltage Cut Out Threshold Voltages The Main Machine Controller intentionally shuts down machine functions in two stages if the battery voltage drops too low This is called Low Voltage Cut Out It is done to preserve the life of the batteries The first stage of low voltage cut out shuts off the scrub function by turning off the scrub brush motors and raising the brush deck It also shuts off the so lution and detergent The vacuum is still allowed to run in order to recover solution that is on the floor The second stage of low voltage cut out turns off the vacuum Wet batteries and Gel batteries use different voltage thresholds Wet Batteries 20 55 V Brushes solution detergent and raises brush deck Gel Batteries 21 75 V Em Wet Batteries 20 40 V Vacuum 2 Gel Batteries 21 60 V Battery Run Time Typical battery run times may be around 2 4 hours Battery Compartment Dimensions Length 24 5 62 23 cm Width 14 25 36 2 cm Height 14 25
101. ference Manuals Nilfisk Models Instructions for Use Form Number 56091000 Parts List Form Number 56042542 Advance Models Instructions for Use Form Number 56041820 e Parts List Form Number 56042535 Conventions Forward backward front rear left or right are intended with reference to the operator s position that is to say in driving position with the hands on the handlebar Transporting the Machine CAUTION Before transporting the machine on an open truck or trailer make sure that e machine is tied down securely e access doors and covers are secured tape and strap as needed If the machine must be towed or pushed make sure the Key Switch is in the OFF position Do not move the machine faster than a normal walking pace 2 3 mph 3 5kph and for short distances only Note Disconnecting the wheel drive motor wiring connector will make a disabled machine easier to push Cautions and Warnings Symbols Nilfisk Advance uses the symbols below to signal potentially dangerous conditions Read this information carefully and take the necessary steps to protect personnel and property DANGER Is used to warn of immediate hazards that will cause severe personal injury or death Form Number 56043150 Page 7 service Manual 5 750 SC800 SC 750 ST 50800 ST AAN WARNING 15 used call attention to a situation that could cause severe personal injury 15 used to call attentio
102. fications Vacuum Motor 66 HP 490 watt three stage Vacuum Performance e Blocked off measured at squeegee hose end 51 2 H20 minimum e With 1 inch hole measured approximately 8 7 20 minimum Vacuum Motor Amp Draw With everything assembled and squeegee off the floor 17 Amps Special Tools e Water Lift Gauge part number 56205281 e 1inch open hole adaptor This be fabricated from a short section of PVC pipe Form Number 56043150 Page 87 service Manual 5 750 SC800 SC 750 ST 50800 ST Scrub System Cylindrical Functional Description The scrub system moves the scrub head up and down and turns the scrub motors on and off at the operator s request to provide floor scrubbing action The brushes spin toward one another at the bottom The head is moved up and down by an electric actuator motor that has integrated position switches The weight of the scrub head provides the downward pressure for scrubbing The actuator linkage is slotted to allow the brush head to float when going over low and high spots on the floor A spring is used to lift just a bit of weight in order to obtain optimal scrub pressure weight Note The cylindrical scrub system does not have an extreme pressure mode e The Main Machine Controller energizes the brush solenoid to turn on the brush motors when the following inputs have been met o Key switch on Operator request o Machine moving signal FOR REV is
103. handle assembly back up into position and loosely install the top mounting bolts 15 Tighten all 4 handle mounting bolts Form Number 56043150 Page 157 service Manual SC750 SC800 SC 750 ST SC800 ST Paddle Centering Springs Non ST models SC750 SC800 In the event that the paddle centering springs and hardware need to be replaced these photos will help you assemble it correctly 1 Carefully remove the attaching screw Pieces will fly apart if you do not retain the springs 2 When reassembling install the lower stack first The shoulder of the nylon washers goes toward the spring Carefully position the pieces so that they stay in place j 17 hami 3 Next prepare the upper stack for assembly as shown Install it and tighten the screw Do not over tighten the screw or it will strip out the tower Form Number 56043150 Page 158 service Manual 5 750 SC800 SC 750 ST 50800 ST Drive Wheel 1 Loosen the three nuts securing the wheel to the hub flange a There are 6 nuts on the outer rim of the wheel Three are for holding the two rim halves together These have standard nuts with star lock washers The other three are for securing the wheel to the hub These have Nylock style nuts 2 Raise the wheel off the ground with a jack and remove the 3 mounting nuts 3 Remove the wheel 4 Reassemble in reverse order Transaxle 1 Empty solution
104. hat is a specific gauge and length An electric actuator is used to move the scrub head up and down The actuator has a DC permanent magnet electric mo tor which is driven by the Main Machine Controller The motor turns a threaded shaft When the threaded shaft turns it moves a threaded rod up and down Since the rod is attached to the deck it moves the deck up and down Inside the actuator housing there are also three position switches which are monitored by the Main Machine Controller One is for the retracted position one for the middle position Normal scrub pressure and one for the Extended position Extreme scrub pressure Each switch is normally closed The threaded rod has a collar on it that opens each switch as it passes by it When the Main Machine Controller sees the middle position switch open it knows that the deck is in the normal scrub position If that was its goal position the controller turns off the motor to stop the deck in that position Form Number 56043150 Page 104 service Manual 5 750 SC800 SC 750 ST 5 800 ST Disassembled Deck Actuator Threaded Shaft Threaded Rod Collar Extended Position Switch Middle Position Switch Position Switch Here is how the circuit works for the actuator The Main Machine Controller directly drives the brush head actuator motor It applies system voltage across the two actuator motor wires to move the motor up It reve
105. he controller does not know which one to believe It realizes there must be a problem and will not move the actuator Form Number 56043150 Page 105 service Manual 5 750 SC800 SC 750 ST 50800 ST scrub System Disc and Cylindrical e Switch Brush Contactor Middle EN 5V Retracted Wht B Brush Head Actuator Main Machine Shown in retracted Controller position Drive Motor Controller Form Number 56043150 Page 106 service Manual 5 750 SC800 SC 750 ST 50800 ST Brush Disc Remove Feature The brush disc remove feature spins the brushes and then brings them to an abrupt stop to release the brushes from the brush plate retaining springs To accomplish this a series of events takes place Step 1 First the Main Machine Controller checks to make sure that the scrub deck is fully raised the charger is not plugged in and that the machine is not moving If all of this is true the controller energizes the brush motor contactor to supply battery positive through its normally open Closed when energized contacts to power up the brushes The brush motor contactor has a second set of contacts which are normally closed Open when energized Brush Remove Step 1 B Key Switch Brush Brush Contactor Motors energized Main Machine Controller Step 2 While the brushes are running the Main Machine Controller energizes the brush remove relay This provides a batt
106. he relay contacts opening the circuit Battery Charger Interlock Circuit Not Plugged Into Power Closed Contacts ie of h Interlock Relay Battery Charger Key CB2 Switch TT Du NK Drive Motor Controller Main Machine Controller Form Number 56043150 Page 55 service Manual 5 750 SC800 SC 750 ST 50800 ST When the battery charger is plugged in the machine will display the type of battery charge profile in use as well as charg ing progress on the LCD display to describe the charging profile in words and a battery icon with to 5 bars to show the charging progress On machines with the optional on board battery charger the battery charger and Main Machine Controller communicate with one another on the WHT BLU wire that runs between them This same circuit is also used for the brush head actua tor position 2 switch input Each time the battery charger is plugged in the charger contacts the controller by sending out a positive voltage on the communication wire to find out what kind of batteries are on the machine It needs to know this in order to use the correct charging profile The controller responds and provides the battery type information it has stored in memory The charger then tells the controller which charging profile it will use and begins charging the batter ies See the Control System Program Options section for information on how to tell the controller what kind of batteries are used in the machi
107. hine is not moving the switch is open There is an internal voltmeter inside the Main Machine Controller that sees 24 volts on the circuit When the machine moves in either direction the switch closes and the voltage drops to 0 volts This tells the main machine controller that the machine is moving However the main machine controller does not know what direction the machine is moving There is another circuit called the REV circuit that provides direction information It works similar to the FOR REV circuit When the machine is stationary or moving forward the switch remains open so the main machine controller sees 24v The switch closes when the machine moves in reverse dropping the voltage to Ov e Stationary Machine Both Inputs 24v e Machine Moving Forward FOR REV Ov REV 24v e Machine Moving in Reverse FOR REV Ov REV Ov Form Number 56043150 Page 146 service Manual 5 750 SC800 SC 750 ST 5 800 ST Drive Motor Circuit Description SC750 and SC800 models Drive Motor Controller Movement and Direction Outputs Main Machine Controller WHT RED WHT ORG Drive Motor Controller FOR REV Switch States for Forward Form Number 56043150 Page 147 service Manual 5 750 SC800 SC 750 ST 50800 ST Powering up the Drive Motor Controller This is the same as the ST models See above section Drive Motor Controller Inputs To drive forward the operator pushes on a drive paddle which rotates the Spee
108. ing Main machine controller Form Number 56043150 Page 136 service Manual 5 750 SC800 SC 750 ST 5 800 ST Removal and Installation Solution Valve 1 Work near a floor drain for convenient clean up if possible 2 Turn the key switch on and lower the brush head by pushing the Scrub On Off switch 3 Unplug the deck actuator to prevent deck from rising 4 Turn the key switch off 5 Close solution shut off valve 6 Remove solution mounting plate screws Remove 2 Screws r F 7 Remove hose clamps and hoses 8 Disconnect electrical connector 9 Reassemble in reverse order Solution Tank 1 Empty recovery and solution tanks 2 Remove brush head 3 Remove brush head actuator 4 Remove recovery tank 5 Remove batteries 6 Remove brush head actuator support a Remove two top bolts b Remove lower through bolt and nut 7 Remove handle assembly Form Number 56043150 Page 137 service Manual 5 750 SC800 SC 750 ST 50800 ST 8 Remove control panel cover 9 Disconnect wiring from electrical components on electrical panel 10 Disconnect the pressure sensor hose at the solution tank end 11 Thread wiring out of solution tank 12 Remove squeegee lift cable 13 Remove solution tank shut off valve elbow from tank 14 Remove 4 solution tank mounting bolts E pc 47 gt T Z q w Tank Mounting DS Bolts 15 Separate tank from frame Specifications e Solut
109. ion valve winding resistance 54 ohms e Solution flow Maximum 0 75 gallons minute e Detergent pump winding resistance 37 ohms Form Number 56043150 Page 138 service Manual 5 750 SC800 SC 750 ST 5 800 ST Squeegee System Functional Description The squeegee collects the water so that the recovery system vacuum can suck it up off the floor and store it in the recov ery tank The squeegee support is spring loaded downward to push the squeegee against the floor and has a pivot point that allows the squeegee to swing around corners The squeegee tool rides along the floor on two small wheels and is raised and lowered with a hand operated lever To prevent damage to the squeegee tool in the event that the tool is caught by an obstacle it is mounted to the support frame in slotted holes and is fastened by two hand tightened wing nuts The squeegee angle can be adjusted for optimum floor wiping The squeegee tool has a front and a rear blade Each blade has 4 working edges that can be used before the blade is replaced The front squeegee blade has slots along the bottom edge to allow the necessary air flow to carry the water The rear squeegee blade edge is flat Component Locations Squeegee Support Away Slots e Squeegee Tool e Tilt Adjustment Knob e Squeegee Lift Lever Squeegee Tool Break Away Tilt Adjustment Slots Knob Form Number 56043150 Page 139 service Manual SC750 SC800
110. ircuit to battery negative whenever the machine is moving The Main Machine Controller has an internal voltmeter that monitors the circuit When it sees 24 volts it knows the machine is standing still When it sees the voltage drop to near zero it knows the machine is moving and it then turns on the solu tion flow To make the solution flow the key switch provides battery positive B voltage to the solution solenoid valve The voltage goes through the solenoid winding and on to the Main Machine Controller The controller completes the circuit to battery negative B through an internal switch causing the solenoid to energize and open the valve If the Form Number 56043150 Page 132 service Manual 5 750 SC800 SC 750 ST 50800 ST machine has the optional detergent mixing system the Main Machine Controller also operates the additional detergent pump The two wires for the pump are wired directly to the Main Machine Controller The Main Machine Controller sup plies battery positive on one wire and battery negative on the other for a short period of time to stroke the piston in one direction It then immediately reverses polarity and does it again to stroke the piston back in the other direction Key Solution System Switch solution Solenoid Main Machine Controller Drive Motor Controller Detergent Pump Circuit Detergent Pump Main Machine Controller Form Number 56043150 Page 133 service Manual SC750 SC800 SC 750 S
111. istor from the controller which returns back to bat tery negative on a common wire to connector J2 pin 2 The controller has internal voltmeters which monitor the signal voltage of each switch circuit When the switch is closed the voltage signal is approximately 0 volts When the switch is open the voltage is approximately 5 volts 1 Deck up Retracted Position switch 5v Other two switches Ov 2 Normal Scrub mode Middle Position switch 5v Other two switches Ov 3 Extreme Scrub mode is not used on Cylindrical Deck Note The actuator extended position switch circuit is unique because it is also used as a communication line between the Main Machine Controller and the battery charger The addition of the battery charger on the circuit drops the 5v that is normally seen when the switch is open to approximately 3 volts This is normal When the key is turned off if the brush head is down the Main Machine Controller will raise the brush head to the full up position When the operator requests the scrub mode the controller drives the actuator down until it sees the Middle Position switch open 5v When the operator turns off the scrub function the controller drives the actuator mo tor up until it sees the Retracted Position switch open again 5v If more than one position switch is open 5v at a time the controller does not know which one to believe It realizes there must be a problem and will not move the actuator
112. itches The Regular Scrub Pressure Indicator will remain on and the Fault Indicator will be flashing a numeric value that repre sents the current setting To change the setting press the solution switch forward to increase the value or backwards to decrease the value To save the setting press the scrub forward All LEDs will turn on then turn off the key switch e 1 blink No 2 blinks Yes Fault Recall The fault indicator normally flashes out current codes only This function is used by a technician to check for historical codes and clear them To check or clear historical codes 1 While pressing and holding the vacuum and solution switches backward and the scrub switch forward turn the key switch on 2 Wait about 3 seconds until all of the LEDs light up and then go off Release the switches The High Solution Flow Indicator will remain on and the Fault Indicator will be flashing out all historical codes set since the last time they were cleared To exit this function without clearing codes press the scrub switch forward To clear historical codes press the solution switch forward Fault Detection Normally the Main Machine Controller will perform checks of the electrical system during operation If a fault occurs in a particular system that system and possibly others will be shut down This can make troubleshooting the system difficult This option will allow service personnel to disable some of the fault
113. ividual battery while operating the machine Write down the values and compare them A battery that has a dead cell will typically be 1 2 volts lower than the others o Use a battery load tester to test each battery o For wet batteries a hydrometer be used to check the specific gravity of the electrolyte in each cell A dead cell is one that reads 50 points or more lower than the other cells e Battery cable connections The Battery Charger Does Not Charge Possible Causes e Battery Charger e Wiring Connections e Batteries Note The optional on board battery charger will charge even if it cannot communicate with the Main Machine Control ler Form Number 56043150 Page 59 service Manual 5 750 SC800 SC 750 ST 50800 ST Removal and Installation Batteries If the set of batteries has 50 or more cycles on them do not put a new battery into the set Either replace with all new batteries or use a good used battery Battery maintenance requirements change as they age As they age they usually require longer charging time and a higher finish rate The newer battery mixed in with old batteries will end up being overcharged which will cause it to fail prematurely WARNING Use extreme caution when working with batteries Sulfuric acid in batteries can cause severe injury if allowed to contact the skin or eyes Explosive hydrogen gas is vented from the batteries through openings in the battery caps This gas can b
114. k for a restriction in the system Form Number 56043150 Page 84 service Manual SC750 SC800 SC 750 ST SC800 ST Removal and Installation Vacuum Motor 1 Turn off key switch drain recovery tank and lift recovery tank up 2 Cuttie straps securing wiring and disconnect vacuum motor electrical connection i sil Cut Strap and Disconnect 3 Remove vacuum motor cover mounting screws and cover Note The vacuum motor cooling fan guard may come off the end of the motor Do not run the motor without the guard in place Make sure that it is put back on dur ing reassembly Cooling Fan Guard Came Off Form Number 56043150 Page 85 service Manual SC750 SC800 SC 750 ST SC800 ST 4 Remove vacuum motor and foam pieces Pay attention to how the foam pieces are positioned 5 Reassemble in reverse order b d Install the cooling fan guard if it is not in place Take care to position all the foam pieces correctly pm Cooling Fan P Guard Make sure the ends of the vacuum motor are seated correctly If you have difficulty seating all of the pieces remove the recovery tank and place it upside down so that the vacuum motor goes in vertically This way you will not be fighting gravity Route the vacuum motor wiring lead in the slot of vacuum motor cover and install foam cooling fan filter Form Number 56043150 Page 86 service Manual SC750 SC800 SC 750 ST SC800 ST Speci
115. l SC750 SC800 SC 750 ST SC800 ST 9 Remove 4 screws securing the Main Machine Controller and remove it from the cover 1 10 Reassemble in reverse order taking not to damage the printed circuit ribbons used to connect the circuit board to the control switch interface panel 11 Set Mandatory Program Options IMPORTANT When a new controller is installed it must first be told how the machine is equipped before it will work The first time the key is turned on the controller wakes up in the pro gramming option mode to force you to complete the settings In this special case you will be walked through setting the Scrub Deck Type and Battery Charger Selection before the machine will operate See Programming Options SC750 ST and SC800 ST Models Control Panel with rocker switches Mandatory Program Options Main Machine Controller SC750 ST and SC800 ST Models Later Build Minor changes were made to the electrical panel cover and circuit breaker panel to make the machine easier to service Follow the instructions for Main Machine Controller SC750 and SC800 Models control Panel with membrane switches Later build with the realization that some of the photos will not exactly match ma chine you are working on Main Machine Controller SC750 and SC800 Models Early Build Note Electronic devices like the Main Machine Controller are sensitive to Electrostatic Discharge ESD Before handling the control
116. l The use of other brushes may impair safety ZX caution This machine is not approved for use on public paths or roads e This machine is not suitable for picking up hazardous dust Use care when using scarifier discs and grinding stones Advance will not be held responsible for any damage to floor surfaces caused by scarifiers or grinding stones e When operating this machine ensure that third parties particularly children are not endangered Form Number 56043150 Page 8 service Manual SC750 SC800 SC 750 ST SC800 ST e 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 removing the key and securing the machine e Turn key switch and remove the key before changing the brushes and before opening any access panels e Take precautions to prevent hair jewelry or loose clothing from becoming caught in moving parts e Use caution when moving this machine in below freezing temperature conditions Any water in the solution or recovery tanks or in the hose lines could freeze causing damage to valves and fittings Flush with windshield washer fluid e The batteries must be removed from the machine before the machine is scrapped The disposal of the batteries should be safely done in accordance with your local environmental regulations Do use surfaces having a gr
117. ler touch a metal bench or shelf to discharge any electrical charge that may have built up in your body Do not walk around with a controller in your hands 1 Completely drain solution tank This is important for the solution level sensor to work properly upon reassembly 2 Turn off and remove key 3 Disconnect Handle electrical connector Remove top two handle bolts and loosen the lower two Rotate Handle Assembly down Form Number 56043150 40 service Manual SC750 SC800 SC 750 ST SC800 ST 4 Remove circuit breaker mounting plate screws Partially remove plate Remove breakers from plate then turn plate and insert into cover opening Remove Circuit Breaker Mounting Plate 5 Remove electrical panel cover mounting screws 6 Tip cover away from machine and disconnect the clear pressure sensor hose from the fitting at the solution tank DO NOT TRY TO DISCONNECT THE HOSE FROM THE CIRCUIT BOARD Disconnect Hose Form Number 56043150 Page 41 service Manual SC750 SC800 SC 750 ST SC800 ST 7 Disconnect electrical connectors from the Main Machine Controller and Key Switch Remove screw securing ground wire to control switch interface panel Location Key Switch Connectors Controller Connectors 4 4 EM GE i 9 8 Remove the electrical panel cover and place on work bench 9 Remove the 5 screws securing the switch panel
118. ler uses to send out to the drive motor The controller wakes up when it receives voltage from the key switch On machines with an optional on board battery charger the voltage first goes through the key switch and then through the interlock circuit in the battery charger when the charger is not plugged into an AC power supply When the charger is plugged in the voltage is interrupted by the built in interlock relay and the drive system will not wake up even if the key is turned on Drive Motor Controller Inputs To drive forward the operator presses either palm drive button and rotates the speed control potentiometer to achieve the desired speed The drive motor controller has internal voltmeters that are monitoring 3 inputs 1 Palm Switches To know when to move 2 Speed Request To know how fast to move 3 Reverse Switch To know which direction to move The palm drive buttons are fed 5 volts from the controller When either switch closes the 5 volts goes through the switch and back to the controller where an internal voltmeter sees the 5 volts and recognizes it as a request to move Note There is an internal diagnostic voltage of a little more than 2 volts that will be seen when both switches are open The speed limit potentiometer is fed 5 volts from the controller on one side of its resistive strip The voltage goes through the resistive strip and returns to battery negative inside the controller The wip
119. low flow the valve is on for about 1 3 of the time and off for 2 3 of the time For medium flow it is on about 2 3 of the time For high flow it is on constantly The solution is intentionally shut off whenever the machine stops moving The optional detergent mixing system automatically mixes water from the solution tank with detergent from a separate detergent container The operator fills the solution tank with water only The machine then automatically mixes the correct amount of detergent and water and delivers it to the scrub brush head A piston type detergent pump is used to inject the detergent into the solution hose The controller keeps track of how many times it has stroked the piston pump and can calculate the level of liquid remaining in the detergent tank based on how many strokes it has counted In order for this to work though the operator must tell the controller when a full detergent tank is installed so that the controller can reset its counter and start again at the beginning The detergent is injected into the solution hose before the solution solenoid valve The water and detergent mixture is then regulated by the solenoid valve Here is how the solution electrical circuit works In order to understand whether the machine is moving or not the Main Machine Controller sends 24v out through a resistor on a WHT RED wire to the drive motor controller The drive motor controller has an internal switch that switches the c
120. move Brush Contactor Relay K3 gt K2 tu Electrical Panel Page 109 service Manual 5 750 SC800 SC 750 ST SC800 ST Troubleshooting Scrub Motors Do Not Turn On Possible Causes e Brush contactor o Open or shorted winding Burned contacts e Wiring e Main Machine Controller Not energizing the brush contactor Drive Motor Controller Not providing machine moving signa Scrub Deck Will Not Raise or Lower Possible Causes e Mechanical binding for the actuator linkage e Brush Head Actuator Check both the motor and the position switches Only one position switch should be open at a time and it should open at the correct position o Actuator Motor Unplug the actuator connector and momentarily supply fused 24v power and ground to two motor terminals to see if the motor will operate Machine harness wire color Pink wire and Gray wire Reverse the polarity to drive it in both directions If the motor will not drive in both directions replace the actuator If it does drive in both directions proceed to check the position switches o Position Switches Access the Main Machine Controller and unplug the electrical connectors Checkthe retracted position switch e Putthe black ohmmeter lead on the Brown wire at the J2 connector pin 2 e Putthe red ohmmeter lead on the White wire at the J2 connector pin 3 e Drive the actuator motor all the way up and down using jumper wires powered by b
121. mp ox 93 Scrub Motors Do Not Turn OH ss ie 54 whan 4e ko wo cb os 93 Brush Head Will Not Raise or Lower 93 Removaland Installation x a e wow d EU UE RR We ROREEEG EROR d o 3 44 AEs ER 95 ge Bee REOR xu m RUE E EERE EERE EERE EB mE ES RHA RESTE mS 95 DIGS Drue 97 DEUS ee ADE EUM REUS UR RE wu dd xm uS 98 Brush Molor as ete ebeeeeende 99 Motor Carbon Brush amp ss vox cw oxow hiik b REOS 4 A 18 101 5 9 108 Scrub Motor Total Amp uxo oo eke ee ROS E ER RR RON 4 Qe 3e we RR m 103 Scrub Motor Speed s va sre ouem ode eom Geox ok XO GR e POR e E ace eode bo 4 4 ox 103 103 Brush Head Actuator Amp 103 l2 COM OCOT 103 PCPA System DISC s x uuuwur doo xU RO X 4 93 4 3x 343 4 9442 935 9x95 x5 104 Functional Description s uou moo ob oed oo 4854 Rm RD RR DSR eRe e 5 OG ww 104 Form Number 56043150 Page iii service Manual 5 750 SC800 SC 750 ST 50800 ST eea l oe ce ee bese e
122. n tank serves as an electrical panel and provides a mounting surface for the vari ous relays fuses and the Drive Motor Controller Circuit breakers and a main fuse protect various circuits from excessive current The machine wiring is color coded and the ends of each wire have the wire identification printed on them such as J1 4 X1 1 The wiring identification information can be used to more easily trace wiring in the machine because it is also shown on the wiring harness configuration diagram Wire Identification Form Number 56043150 Page 54 service Manual 5 750 SC800 SC 750 ST 50800 ST On board Battery Charger An optional on board battery charger is available on Non ST models When equipped it is mounted on the bottom of the machine The charger has an internal relay that interrupts power to the on board when the charger is plugged into an AC power outlet This is called the Interlock circuit on the wiring diagram It prevents the machine from being oper ated while the batteries are charging Wiring changes must be made when installing the battery charger for the interlock circuit to work correctly Here is how the battery charger interlock circuit works The interlock relay contacts inside the charger are normally closed allowing the current to pass in and out of the charger to the Main Machine Controller and the Drive Motor Con troller When the AC power cord is plugged in the relay is energized and opens t
123. n to a situation that could cause minor personal injury or damage to the machine or other erty 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 ZAN warning This machine should only be used by properly trained and authorized persons e While on ramps or inclines avoid sudden stops when loaded Avoid abrupt sharp turns Use low speed down hills Clean only while ascending driving up the ramp e Keep sparks flame and smoking materials away from batteries Explosive gases are vented during normal opera tion e Charging the batteries produces highly explosive hydrogen gas Charge batteries only in well ventilated areas away from open flame Do not smoke while charging the batteries e Remove all jewelry when working near electrical components e Turn the key switch and disconnect the batteries before servicing electrical components e Never work under a machine without safety blocks or stands to support the machine Do dispense flammable cleaning agents operate the machine on or near these agents or operate in areas where flammable liquids exist Do not clean this machine with a pressure washer Do not operate this machine on ramps or inclines of more than 2 percent gradient e Only use the brushes provided with the appliance or those specified in the instruction manua
124. ne If the charger is unable to communicate with the controller it will use the profile for a wet bat tery at a 25 Amp rate as a default Form Number 56043150 Page 56 service Manual 5 750 SC800 SC 750 ST 5 800 ST Component Locations Batteries Sp Batteries Main Battery Pack Connector Battery Charger Optional Electrical Panel Main Fuse Battery Negative Stand Off Circuit Breakers 0 T 4 Form Number 56043150 Connection Diagram Battery Charger Circuit Breakers Main Battery Pack Connector Electrical b Panel C Main Fuse Negative otand Off Page 57 service Manual 5 750 SC800 SC 750 ST 5 800 ST Electrical Panel Components Vacuum Relay Brush Remove K4 150 Amp Fuse Relay F1 Brush Contactor K2 Drive Motor Controller A2 p gt Form Number 56043150 Page 58 service Manual 5 750 SC800 SC 750 ST SC800 ST Maintenance and Adjustments Battery Maintenance and Recharging See Instructions for Use Manual Troubleshooting Insufficient Machine Operation Time Possible Causes e Incorrect low voltage cutout setting e Batteries not fully charged If there is any question whether the batteries are fully charged they should be charged for at least 16 hours more weak batteries determine if one of the batteries is weak measure the voltage across each ind
125. ng 2 4 Brush Motor Circuit The Main Machine Controller has energized the Brush Open Contactor but it is not sensing any current flow through the brush motor ground circuit for at least 5 seconds Senses lt 4 Amps for 5 seconds and code 35 is not ac tive A I m a M N E Check Motor Contactor contacts Wiring Form Number 56043150 Page 23 service Manual 5 750 SC800 SC 750 ST 5 800 ST LCD ST Code Display Blink Definition Code Code Scrub Deck Lift Actuator Circuit Open UW N Vacuum Motor Circuit Open Ww UJ w N Brush Contactor Coil Circuit Open w Vacuum Contactor Coil Circuit Open N A Detergent Pump Circuit Open Brush Remove Contactor Coil Circuit Open N A 3 4 Brush Motor Contactor Stuck Closed 3 5 Vacuum Motor Contactor Stuck Closed Form Number 56043150 Explanation Code Setting Conditions Flash Indicator Disables Check The Main Machine Controller is trying to move the actua tor but it is not sensing any current flow Senses 100 m Amps for 5 seconds Check Actuator wiring The Main Machine Controller has energized the Vacuum Contactor but it is not sensing any current flow through the vacuum motor ground circuit for at least 5 seconds Senses 3 Amps for 5 second and Fault Code 36 is not active Check motor wiring The Main Machine Controller has
126. off the key switch e 1blink No pressure setting locked out e 2 blinks Low pressure setting locked out e 3 blinks High pressure setting locked out Form Number 56043150 Page 30 service Manual 5 750 SC800 SC 750 ST 50800 ST Lock Out Solution Flow Rate is possible to lock out any one or more of the solution flow rate settings During normal operation the flow rate s that are locked out will not be able to be selected To check or change the setting 1 While pressing and holding the vacuum and solution switches forward and the scrub switch backwards turn the key switch on 2 Wait about 3 seconds until all of the LEDs light up and then go off Release the switches The Vacuum Indicator will remain on and the Fault Indicator will be flashing a numeric value that represents the cur rent setting To change the setting press the solution switch forward to increase the value or backwards to decrease the value To save the setting press the scrub switch forward All LEDs will turn on then turn off the key switch e 1 blink No flow rate locked out 2 blinks Low flow rate locked out 3 blinks Medium flow rate locked out e 4 blinks High flow rate locked out 5 blinks Low and medium flow rates locked out e 6 blinks Low and high flow rates locked out 7 blinks Medium and high flow rates locked out Recovery Tank Full Enable Disable It is possible to enable or disable the Recovery Tank
127. on and the fault indicator will be flashing a numeric value that represents the cur rent setting To change the setting press the solution switch forward to increase the value or backwards to decrease the value To save the setting press the scrub switch forward All LEDs will turn on then turn off the key switch 1 blink Not equipped with on board charger e 2 blinks On board charger with WET 25 batteries Use with 242 AH WET Batteries 56206079 or 310 WET Batteries 56391391 e 3 blinks On board charger with AGM DISCOVER 25 batteries Use with 312 AH AGM Batteries 56315959 Form Number 56043150 Page 29 service Manual 5 750 SC800 SC 750 ST 50800 ST 4 blinks On board charger with GEL EXIDE 25A batteries 5 blinks On board charger with GEL AGM 25A batteries 6 blinks On board charger with WET 15A batteries 7 blinks On board charger with GEL AGM 15A batteries Additional Program Options The following options can be used by the technician or to set user preferences Low Voltage Cut Out Selection The purpose of the low battery voltage cutout function is to help prolong battery life The scrub deck will be raised and the brush motors vacuum motor and solution solenoid valve will turn OFF automati cally and cease to function when the batteries discharge to the selected cutout level The cutout level is adjustable between two settings The standard setting wet cell lead acid is 20 55 volts and alternate se
128. otor removed from the machine for better clarity 1 Remove the plastic motor cover 2 Remove wiring from motor connectors 3 Remove one of the round plastic brush caps using a large slotted screw driver 5 Reassemble in reverse order lining up the two locking tabs of the brush cap when installing the brush peat for second carbon brush Form Number 56043150 Page 113 service Manual 5 750 SC800 SC 750 ST 5 800 ST Brush Head Actuator 1 Empty recovery tank 2 Press the scrub button to lower the brush head a Ifthe actuator does not move slightly raise the brush head with a jack to take tension off of the mount ing hardware 3 Lift recovery tank up 4 Disconnect electrical connector so the actuator will not move and then turn the key off 5 Remove upper and lower fasteners 6 Remove actuator 7 Reassemble in reverse order Form Number 56043150 Page 114 service Manual 5 750 SC800 SC 750 ST 5 800 ST Specifications Scrub Motor Amp Draw No Load Approximately 4 Amps Scrub Motor Total Amp Draw Total amp draw in regular scrub mode with low solution flow for all size decks ranges from 15 30 Amps depending on the floor surface Total amp draw in extreme scrub mode with low solution flow for all size decks ranges from 30 45 Amps depending on the floor surface Scrub Motor Speed 260 270 RPM Scrub Force Regular Scrub 80 165 36 3 kg Extreme Scrub 170 lbs 77
129. ow wire at the J2 connector pin 11 e Drive the actuator motor all the way up and down using jumper wires powered by bat tery positive and negative Connect them to the two actuator motor wires at the Main Machine Controller connector Pink wire at connector J1 pin 4 and Gray wire at connec tor J1 pin 5 Change polarity to change direction Immediately remove jumper wires at the end of motor travel e Monitor the ohmmeter It should show an open circuit no continuity only when the actuator is in the middle position In all other positions it should show a closed circuit continuity Check the extended position switch Put the black ohmmeter lead on the Brown wire at the J2 connector pin 2 Put the red ohmmeter lead on the Green wire at the J2 connector pin 12 e Drive the actuator motor all the way up and down using jumper wires powered by bat tery positive and negative Connect them to the two actuator motor wires at the Main Machine Controller connector Pink wire at connector J1 pin 4 and Gray wire at connec tor J1 pin 5 Change polarity to change direction Immediately remove jumper wires at the end of motor travel e Monitor the ohmmeter It should show an open circuit no continuity only when the actuator is in the extended position In all other positions it should show a closed circuit continuity e Wiring e Main Machine Controller Form Number 56043150 Page 94 service Manual 5 750 SC800 SC 750 ST 5 8
130. own The actuator has a DC permanent magnet electric mo tor which is driven by the Main Machine Controller The motor turns a threaded shaft When the threaded shaft turns it moves a threaded rod up and down Since the rod is attached to the deck it moves the deck up and down Inside the actuator housing there are also three position switches which are monitored by the Main Machine Controller One for the retracted position one for the middle position Normal scrub pressure and one for the Extended posi tion Extreme scrub pressure Each switch is normally closed The threaded rod has a collar on it that opens each switch as it passes by it When the Main Machine Controller sees the middle position switch open it knows that the deck is in the normal scrub position If that was its goal position the controller turns off the motor to stop the deck in that posi tion Form Number 56043150 Page 88 service Manual 5 750 SC800 SC 750 ST 5 800 ST Disassembled Deck Actuator Threaded Shaft Threaded Rod Retracted Position Switch Extended Position Switch Middle Position Switch Here is how the circuit works for the actuator The Main Machine Controller directly drives the brush head actuator mo tor It applies system voltage across the two actuator motor wires to move the motor up It reverses polarity to move the motor down Each position switch receives a 5 volt feed through a res
131. puts have been met e Key switch on e Operator request e Machine moving signal FOR REV is received from the Drive Motor Controller A2 PG Drives Speed Controller o Approximately 24 volts received from the main controller J3 Pin 6 is switched to battery negative by the Drive Motor Controller dropping the voltage to 0 volts Here is how the circuit works for the scrub motors The Main Machine Controller turns on the scrub motors indirectly by energizing the brush contactor The brush contactor coil is fed battery positive voltage through the key switch The voltage goes through the coil and on to the controller Inside the controller it switches the circuit to battery negative to energize the relay When the relay energizes positive battery voltage is applied through its contacts to the brush motors Since the other side of the motors is connected to battery negative they turn on The Main Machine Controller also monitors the amount of electrical current Amps that is flowing through the brush motor ground circuit If it is higher or lower than expected a fault code will be set It monitors the amperage indirectly ona sense wire by measuring the difference in voltage Voltage Drop between a point near the motors and the main battery negative terminal As actual current increases the voltage drop measured increases The controller then converts the voltage value to Amps The monitoring circuit relies on a calibrated ground wire t
132. r The brush contactor coil is fed battery positive voltage through the key switch The voltage goes through the coil and on to the controller Inside the controller it switches the circuit to battery negative to energize the relay When the relay energizes positive battery voltage is applied through its contacts to the brush motors Since the other side of the motors is connected to battery negative they turn on The Main Machine Controller also monitors the amount of electrical current Amps that is flowing through the brush motor ground circuit If it is higher or lower than expected a fault code will be set It monitors the amperage indirectly ona sense wire by measuring the difference in voltage Voltage Drop between a point near the motors and the main battery negative terminal As actual current increases the voltage drop measured increases The controller then converts the voltage value to Amps The monitoring circuit relies on a calibrated ground wire that is a specific gauge and length An electric actuator is used to move the scrub head up and down The actuator has a DC permanent magnet electric mo tor which is driven by the Main Machine Controller The motor turns a threaded shaft When the threaded shaft turns it moves a threaded rod up and down Since the rod is attached to the deck it moves the deck up and down Inside the actuator housing there are also three position switches which are monitored by the Main Machine Con
133. received from the Drive Motor Controller 2 PG Drives Speed Con troller Approximately 24 volts received from the main controller J3 Pin 6 is switched to battery nega tive by the Drive Motor Controller dropping the voltage to O volts Here is how the circuit works for the scrub motors The Main Machine Controller turns on the scrub motors indirectly by energizing the Brush Contactor The brush contactor coil is fed battery positive voltage through the key switch The voltage goes through the coil and on to the controller Inside the controller it switches the circuit to battery negative to energize the relay When the relay energizes positive battery voltage is applied through its contacts to the brush motors Since the other side of the motors is connected to battery negative they turn on The Main Machine Controller also monitors the amount of electrical current Amps that is flowing through the brush motor ground circuit If it is higher or lower than expected a fault code will be set It monitors the amperage indirectly on a sense wire by measuring the difference in voltage Voltage Drop between a point near the motors and the main battery negative terminal As actual current increases the voltage drop measured increases The controller then converts the voltage value to Amps The monitoring circuit relies on a calibrated ground wire that is a specific gauge and length An electric actuator is used to move the scrub head up and d
134. res are removed then remove the wires b Fully seat the end cover 8 Install the through bolts 9 Seal the retaining wire holes in the end cover with silicone sealant Form Number 56043150 Page 102 service Manual 5 750 SC800 SC 750 ST 5 800 ST Specifications Scrub Motor Total Amp Draw Typical total amp draw for both 28 inch and 32 inch decks ranges from 45 Amps to 65 Amps when scrubbing with low solution flow depending on the type of floor Scrub Motor Speed 830 840 RPM Scrub Force 80 Ibs 36 3 kg Brush Head Actuator Amp Draw Upward with weight of deck Approximately 1 2 Amps Brush Contactor Winding Resistance 55 ohms Form Number 56043150 Page 103 service Manual 5 750 SC800 SC 750 ST 5 800 ST Scrub System Disc Functional Description Scrubbing The scrub system moves the scrub head up and down and turns the scrub motors on and off at the operator s request to provide floor scrubbing action The discs spin toward the center at the front edge of each disc The head is moved up and down by an electric actuator motor that has integrated position switches The weight of the scrub head provides the downward pressure in the normal scrub mode When extreme pressure is requested the actuator moves down farther Causing a gas spring to exert additional downward pressure on the floor The Main Machine Controller energizes the brush solenoid to turn on the brush motors when the following in
135. res the control unit current settings flow rate settings and scrub pressure settings for each of the scrub deck types e REV 2 Deck 28INCH 71 cm CYL or 28 INCH CYL BA756C Early models 32 INCH 81 CYL 32 INCH CYL Early models 26 66 cm DISC 26 INCH DISC Early models e 28 INCH 71cm DISC or 28 INCH DISC BA756 Early models 34 INCH 86 DISC or 34 INCH DISC BA856 Early models To change the setting 1 Scroll through the menu using the Solution Increase and Decrease switches until you get to the desired value 2 save and go back to the main menu press the scrub ON OFF switch MACHINE PLATFORM This function configures the control unit for the machine size Early model display names are different Select between 21 gallon medium platform machine SC750 SC750 ST or 25 gallon large platform machine SC800 SC800 ST This setting will affect the solution level solution and chemical flow rate calculations in the firmware 5 750 21 GAL 80 LTR or MX 21 GAL 80 LITRE Early models 5 800 25 GAL 95 LTR or LX 25 GAL 95 LITRE Early models To change the setting 1 Scroll through the menu using the Solution Increase and Decrease switches until you get to the desired value 2 Tosave and go back to the main menu press the scrub ON OFF switch CHEMICAL SELECTION This function is used to let the controller know whether or not the machine is equipped with the optional
136. rses polarity to move the motor down Each position switch receives a 5 volt feed through a resistor from the controller which returns back to battery negative on a common wire to connector J2 pin 2 The controller has internal voltmeters which monitor the signal voltage of each switch circuit When the switch is closed the voltage signal is approximately 0 volts When the switch is open the voltage is approximately 5 volts 1 Deck up Retracted Position switch 5v Other two switches Ov 2 Normal Scrub mode Middle Position switch 5v Other two switches Ov 3 Extreme Scrub mode Extended Position switch 5v Other two switches Ov Note The actuator extended position switch circuit is unique because it is also used as a communication line between the Main Machine Controller and the battery charger The addition of the battery charger on the circuit drops the 5v that is normally seen when the switch is open to approximately 3 volts This is normal When the key is turned off if the brush head is down the Main Machine Controller will raise the brush head to the full up position When the operator requests the scrub mode the controller drives the actuator down until it sees the Middle Position switch open 5v When the operator turns off the scrub function the controller drives the actuator mo tor up until it sees the Retracted Position switch open again 5v If more than one position switch is open 5v at a time t
137. rvice Manual SC750 SC800 SC 750 ST SC800 ST Indicator Lights All indicator lights illuminate for 2 seconds when the key is first turned on Solution Flow Indicators No flow None lit Low flow Bottom one lit Medium flow Bottom two lit High flow All lit Scrub Pressure Indicators Regular Scrub Pressure Bottom one lit Extreme Scrub Pressure Both lit Vacuum Indicator Vacuum on On Vacuum off Off Time Delay before shut off Flashing Battery Indicator Shows current battery condition o Green Full o Yellow Medium Red Low Flashing Red Low Voltage Cut Out Mode Fault Code Indicator Normal Operation o Off No Codes o Flashing Code display Will light up if the key is switched on while charging the battery Displays the currently selected setting when in hidden menu operations Form Number 56043150 Page 14 service Manual 5 750 SC800 SC 750 ST 5 800 ST Machine Specifications 5 750 and SC750 ST See other system chapters for specifications not listed here Model Name Model Number SC750 SC 750 ST A Sound Pressure Level dB A 61 dB A IEC 60704 1 Gross Weight standard machine with charger w full solution tank empty recovery tank and heavi lbs kg 942 165 427 3 est batteries installed Net Weight machine w o options batteries or removable brushes w empty solution and recov lbs kg 347 lbs 157 4
138. s when shorter than 3 8 9 5mm to obtain the same motor efficiency as new brushes Important Motor damage resulting from failure to service the carbon brushes is not covered under warranty See the Limited War ranty Statement Form Number 56043150 Page 17 service Manual 5 750 SC800 SC 750 ST SC800 ST Lubricating the Machine Once a month apply light machine oil to lubricate the D e General Pivot Points for the Squeegee Linkage A s e Squeegee mount angle adjustment knob threads B e Squeegee Tool end wheels SoG B 2 C e General Pivot Points for the Brush Linkage D 5 e Scrub deck bumper wheels i P Once per quarter grease the following C E e Rear Caster Wheel Swivels E LF AAN WARNING Turn the key switch off and disconnect the batteries before servicing the machine Form Number 56043150 Page 18 service Manual 5 750 SC800 SC 750 ST 50800 ST Chassis System Functional Description The chassis is made up of heavy gauge steel and supports the drive transaxle caster wheel brush deck squeegee assem bly and machine body Form Number 56043150 Page 19 service Manual 5 750 SC800 SC 750 ST 50800 ST Control system Functional Description There are two controllers on the machine a Main Machine Controller and a Drive Motor Controller The Main Machine Controller operates the floor cleaning functions of scrub solution
139. setting AGM is 21 75 volts e WET BATTERY 80 20 55V e MAIN FREE BATTERY 70 LVC 21 75V To change the setting 1 Scroll through the menu using the Solution Increase and Decrease switches until you get to the desired value 2 save go back to the main menu press the scrub ON OFF switch Form Number 56043150 Page 35 service Manual 5 750 SC800 SC 750 ST SC800 ST Additional Program Options The following options can be used to set user preferences LOCKOUT BRUSH PRE For disc brush decks only it is possible to lock out either the Low or High Brush Pressure setting During normal operation the pressure setting s that are locked out will not be able to be selected e NONE e LOW e HIGH To change the setting 1 Scroll through the menu using the Solution Increase and Decrease switches until you get to the desired value 2 save and go back to the main menu press the scrub ON OFF switch LOCKOUT SOL FLOWS It is possible to lock out any or more of the Solution Flow Rate settings During normal op eration the flow rate s that are locked out will not be able to be selected e NONE e LOW e MEDIUM e HIGH e LOW amp MEDIUM e LOW amp HIGH e MEDIUM amp HIGH To change the setting 1 Scroll through the menu using the Solution Increase and Decrease switches until you get to the desired value 2 Tosave and go back to the main menu press the scrub ON OFF switch RECOVER TANK FUL
140. t the black ohmmeter lead on the Brown wire at the J2 connector pin 2 Put the red ohmmeter lead on the White wire at the J2 connector 3 e Drive the actuator motor all the way up and down using jumper wires powered by bat tery positive and negative Connect them to the two actuator motor wires at the Main Machine Controller connector Pink wire at connector J1 pin 4 and Gray wire at connec tor J1 pin 5 Change polarity to change direction Immediately remove jumper wires at the end of motor travel e Monitor the ohmmeter It should show an open circuit no continuity only when the actuator is in the retracted position In all other positions it should show a closed circuit continuity Form Number 56043150 Page 120 service Manual 5 750 SC800 SC 750 ST 5 800 ST e Wiring Check the middle position switch Put the black ohmmeter lead on the Brown wire at the J2 connector pin 2 Put the red ohmmeter lead on the Yellow wire at the J2 connector pin 11 Drive the actuator motor all the way up and down using jumper wires powered by bat tery positive and negative Connect them to the two actuator motor wires at the Main Machine Controller connector Pink wire at connector J1 pin 4 and Gray wire at connec tor J1 pin 5 Change polarity to change direction Immediately remove jumper wires at the end of motor travel Monitor the ohmmeter It should show an open circuit no continuity only when the actuator is in the middle
141. tentiometer R4 Resistor 2 Inside Handle Form Number 56043150 Page 150 service Manual 5 750 SC800 SC 750 ST 5 800 ST Troubleshooting The Drive speed Controller does not support fault codes If there is a problem with the system the diagnostic approach is to check drive system inputs and outputs Does Not Propel Forward or Reverse Possible Causes Battery voltage too low Controller not receiving input requests for travel Drive motor Drive motor controller Wiring If the drive system is not functional but the rest of the machine control panel operates use the Service Test Mode to speed your diagnosis Check to see if the Drive Motor Controller is sending signals to the Main Machine Controller that indicate it is trying to move the machine If it is that confirms that the input requests to the Drive Motor Controller are good and that it is trying to respond to them Next check to see if there is voltage across the motor terminals If the voltage is above 6 volts and the motor is not turning the motor is the problem Check the carbon brushes If there is no voltage to the motor the controller or wiring has failed Form Number 56043150 Page 151 service Manual SC750 SC800 SC 750 ST SC800 ST Removal and Installation Speed Limit Potentiometer ST models 1 2 Loosen set screw and remove knob Remove potentiometer mounting nut and washer Remove upper handle bolts Loosen lower handle bolts
142. tion Flow indicators will remain on and the fault indicator will flash out the revision code Programming Options 5 750 and SC800 models Control Panel with membrane switches Main Machine Controller special program options allow the service repairperson to match the control board to the spe cific model equipment and to user preferences They also allow adjustments to some machine functions and provide a way to see the controller s revision level On SC750 and SC800 models all program option modes are entered through a hidden menu that is displayed on the LCD To enter the Programming Options mode Start with the battery charger unplugged and the key off 1 Press and hold the scrub ON OFF switch and Vacuum Wand switch together 2 While holding both switches turn the Key Switch to the ON position 3 Continue to hold both switches about 3 seconds until the display shows Programming Options then release the switches 4 Scroll through the menu using the Solution Increase and Decrease switches until you get to the desired program ming option 5 Press the Solution On Off switch to enter the mode Form Number 56043150 Page 33 service Manual 5 750 SC800 SC 750 ST 50800 ST Mandatory Program Options These options must be set to correctly match the Main Machine Controller to the machine DECK TYPE There 5 possible scrub deck options Early model display names are different This function configu
143. tool will reduce its ability to pick up water Anything that restricts the movement of air through the system will also reduce its ability to pick up water Possible Causes e Restricted air flow o Clogged or kinked squeegee vacuum hose o Clogged vacuum motor inlet or outlet port e Damaged squeegees e Air leaks o Recovery tank lid gasket is not sealing o Cracked squeegee vacuum hose o Cracked recovery tank e Vacuum motor is weak 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 hole adapter See the Special Tools Section below The adapter can be made from a piece of PVC pipe 1 Remove the vacuum hose from the squeegee tool Form Number 56043150 Page 83 service Manual 5 750 SC800 SC 750 ST 50800 ST 2 Hold the vacuum gauge against the end of the hose and turn on the vacuum motor Note the reading on the gauge If it is within 10 of specs go to the next step If it is too low check for air leaks in the system 3 Install a one inch open hole adapter between the hose end and the vacuum gauge 4 Turnthe vacuum motor on and measure the vacuum If it is within 10 of the specs the vacuum system is work ing properly If the reading is too low chec
144. tor Amp Draw Measurements e No load one wheel jacked up jumped directly to battery Approximately 1 8 amps e Traversing on level floor with empty tanks driven by Drive Motor Controller at highest speed Approximately 4 5 amps Note Amp draw is higher when getting up to speed approximately 10 12 amps Potentiometers Speed Limit Potentiometer 100K ohms Paddle Position Potentiometer 5K ohms Form Number 56043150 Page 161
145. tor Circuit Description SC750 ST SC800 ST models 144 Drive Motor Circuit Description SC750 SC800 models 147 Component 150 TrOUDICSHOUDLHE 4 wo 9 Roe 49 RR RARER 409 9 9 151 Does Not Propel Forward or 151 Removaland Installation xe nur deor Poem 9 POR YS 152 Speed Limit Potentiometer ST models 132 Speed Limit Potentiometer Non ST models 152 Reverse Switch ST models 0 0 158 Handle Wiring Connections ST models 154 Paddle Position Sensor Non ST models SC750 5 800 155 Paddle Centering Springs Non ST models 5 750 5 800 158 Drive Wheels s ace nea hehe isit 8 4 159 cea bee eee eee ee TS x49 4 9 Ree SESE RE m eee 159 Transaxle Drive Motor Carbon 160 ee eee eee eee ee eee 161 Form Number 56043150 Page v service Manual SC750 SC800 SC 750 ST SC800 ST General Information Service Manual Purpose and Application This
146. troller One is for the retracted position one for the middle position Normal scrub pressure and one for the Extended position Extreme scrub pressure Each switch is normally closed The threaded rod has a collar on it that opens each switch as it passes by it When the Main Machine Controller sees the middle position switch open it knows that the deck is in the normal scrub position If that was its goal position the controller turns off the motor to stop the deck in that position Form Number 56043150 Page 116 service Manual 5 750 SC800 SC 750 ST 5 800 ST Disassembled Deck Actuator Threaded Shaft Threaded Rod Collar Extended Position Switch Middle Position Switch Position Switch Here is how the circuit works for the actuator The Main Machine Controller directly drives the brush head actuator motor It applies system voltage across the two actuator motor wires to move the motor up It reverses polarity to move the motor down Each position switch receives a 5 volt feed through a resistor from the controller which returns back to battery negative on a common wire to connector J2 pin 2 The controller has internal voltmeters which monitor the signal voltage of each switch circuit When the switch is closed the voltage signal is approximately 0 volts When the switch is open the voltage is approximately 5 volts 1 Deck up Retracted Position switch 5v Other
147. ttaching the ground wire to the brush head Remove Remove Hose Clamp Ground Wire and Hose Fastener S 4 Remove the through bolt that attaches the brush head to the lift mechanism bracket Pay attention to the orientation of the washers and bushings 5 Carefully cut the tie straps around the brush motor wire loops Do not damage the wires 6 Raise the lift bracket mechanism with your hand and slide the brush head assembly forward until it clears the machine 7 Reassemble in reverse order Form Number 56043150 Page 122 service Manual 5 750 SC800 SC 750 ST 50800 ST Brush Motor 1 Remove the Brush Head from the machine See Removal and Installation Brush Head 2 Flip the deck disc side up and remove the pads 3 Remove the pad holder by removing the 6 attaching screws 4 To DI wl 5 Liftthe driver motor with the eccentric from the brush motor shaft being careful not to lose the square cut key Driver Moo Eccentric Reg 7 E Form Number 56043150 Page 123 service Manual 5 750 SC800 SC 750 ST 5 800 ST 6 Note the orientation of the brush motor electrical leads relative to the deck to make sure you install the motor in the same position You may want to mark the orientation of the brush motor to the motor plate Then separate the brush motor from the motor plate by removing the 4 attaching screws and remove the motor 7 Reassemble in reverse order noting the following
148. ttery negative inside the controller The wiper inside the potentiometer will return a voltage back to the controller as a speed request input If the wiper is close to the supply side the voltage will be high 4 6v Maximum speed request If it is close to the battery negative return side the voltage will be low 0 2v Minimum speed request The combination of the drive paddle position potentiometer input and the speed limit potentiometer input allows the operator to hold the paddle all the way forward for normal operation while still being able to adjust the travel speed Drive Motor Controller Outputs e This is the same as the ST models See section above Form Number 56043150 Page 148 service Manual 5 750 SC800 SC 750 ST SC800 ST Drive Motor Control Circuit Forward Direction Non ST Models 5 50 5 800 Drive Motor Controller Drive Motor Drive Paddle Potentiometer speed Limit Potentiometer Form Number 56043150 Page 149 service Manual 5 750 SC800 SC 750 ST 5 800 ST Component Locations e Transaxle Wheel Drive Motor e Speed Limit Potentiometer ST e Drive Motor Controller e Palm Drive Switches ST Speed Limit Potentiometer SC750 and SC800 Reverse Switch ST e Drive Paddle Position Sensor SC750 and SC800 R4 Resistor ST Drive Motor Controller Drive Paddle Position Sensor Inside Paddle Palm Drive Switches Speed Limit Potentiometer Speed Limit Po
149. tting AGM is 21 75 volts To check or change the setting 1 While pressing and holding the vacuum and scrub switches backward turn the key switch on 2 Wait about 3 seconds until all of the LEDs light up and then go off Release the switches The yellow Battery Indicator will remain on and the fault indicator will be flashing a numeric value that represents the current setting To change the setting press the solution switch forward to increase the value or backwards to decrease the value To save the setting press the scrub switch forward All LEDs will turn on then turn off the key switch e 160 Wet Battery 8096 20 55V 2 blinks Maintenance Free Battery 7096 21 75V Lock Out Brush Pressure It is possible to lock out either brush pressure setting Low or High During normal operation the brush pressure that is locked out will not be able to be selected To check or change the setting 1 While pressing and holding the vacuum and solution switches backward turn the key switch on 2 Wait about 3 seconds until all of the LEDs light up and then go off Release the switches The green Battery Indicator will remain on and the fault indicator will be flashing a numeric value that represents the cur rent setting To change the setting press the solution switch forward to increase the value or backwards to decrease the value To save the setting press the scrub switch forward All LEDs will turn on then turn
150. ut 5 Remove squeegee support assembly 6 Reassemble in reverse order a Cut wire used to hold spring tension Squeegee Blades Squeegee blades have 4 working edges As an edge becomes worn the blade should be removed and rotated so that a new edge is against the floor facing forward Front Squeegee Blade 1 Remove squeegee tool 2 Loosen the tension strap screw 3 Remove the tension strap 4 Remove the blade 5 Install blade on tool being careful to match the alignment f pm Tension slots Strap Screw 6 Install the tension strap Form Number 56043150 Page 141 service Manual 5 750 SC800 SC 750 ST SC800 ST 7 Tighten the tension strap screw Rear Squeegee Blade 1 Remove squeegee tool 2 Unsnap the center latch 3 Remove the tension straps 4 Remove the blade 5 Install blade on tool being careful to match the alignment slots 6 Install the tension straps 7 Snap the center latch closed Form Number 56043150 Page 142 service Manual 5 750 SC800 SC 750 ST 50800 ST Wheel System Non Traction Functional Description A single caster wheel mounted to the back of the frame allows the machine to pivot easily The wheel is attached with 4 bolts that are screwed into threaded holes in the frame Component Locations e Caster Wheel Form Number 56043150 Page 143 service Manual 5 750 SC800 SC 750 ST 50800 ST Wheel System Traction Functional Description A permanent magn

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