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scrubtec 545b / 545bl / 553b / 553bl / boost 5 / 653b

1. E E e cea ip REG 9 e 5 1 323 760 mm a E E E L DIMENSIONS SCRUBTEC 651BCL it 2 Y JAN Q e JE ki a 4 Li ZIN a 1 253 760 mm E yo Lo L SCRUBTEC 545B 545BL 553B 553BL BOOST 5 9097062000 2 2009 06 14 653B 65381 651BCL 661BL 545E 553E 653E SERVICE MANUAL ENGLISH DIMENSIONS SCRUBTEC 661BL MAINTENANCE GEN LI 2 1 311
2. 34 BRUSH PAD HOLDER DECK OR CYLINDRICAL BRUSH DECK DISASSEMBLY ASSEMBLY SCRUBTEC 545B 545BL 5538 553BL BOOST 5 35 BRUSH PAD HOLDER DECK OR CYLINDRICAL BRUSH DECK DISASSEMBLY ASSEMBLY SCRUBTEC 653B 653BL 651BCL 661 36 BRUSH PAD HOLDER DECK DISASSEMBLY ASSEMBLY SCRUBTEC 545E 553E 653 37 BRUSH MOTOR ELECTRICAL INPUT CHECK SCRUBTEC 5458 545BL 5538 553BL BOOST 5 39 BRUSH MOTOR ELECTRICAL INPUT CHECK SCRUBTEC 6538 6538 40 BRUSH MOTOR ELECTRICAL INPUT CHECK SCRUBTEC 651 sse eene 0000 nennen 41 BRUSH MOTOR ELECTRICAL INPUT CHECK SCRUBTEC 661BL sse nennen nennen nre nnns enne nnn nnns 42 BRUSH MOTOR ELECTRICAL INPUT CHECK SCRUBTEC 545E 553 65 43 BRUSH MOTOR CARBON BRUSH CHECK REPLACEMENT SCRUBTEC 545B 545BL 5538 55381 45 BRUSH MOTOR CARBON BRUSH CHECK REPLACEMENT SCRUBTEC 6538 653BL 46 BRUSH MOTOR CARBON BRUSH CHECK REPLACEMENT SCRUBTEC 651 2 47 BRUSH MOTOR CARBON BRUSH CHECK REPLACEMENT SCRUBTEC 661 48 BRUSH MOTOR DISASSEMBL
3. 76 ELECTRICAL SYSTEM 77 MACHINE WORKING HOUR CHECK SCRUBTEC 5458 545BL 5538 553BL BOOST 5 6538 653BL 651BCL 661BL equipped with optional hour counter 77 MACHINE WORKING HOUR CHECK SCRUBTEC 545E 553E 653E equipped with optional hour counter 77 POWER SUPPLY CABLE CHECK SCRUBTEC 545 553 6536 77 BATTERY CHARGE AND MAINTENANCE All 77 BATTERY DISASSEMBLY ASSEMBLY SCRUBTEC 5458 545BL 5538 553BL BOOST 5 6538 653BL 651BCL 661 78 BATTERY TYPE SETTING WET GEL SCRUBTEC 5458 5538 6538 79 BATTERY TYPE SETTING WET OR GEL SCRUBTEC 545BL 553BL BOOST 5 653BL 651BCL 661BL 80 FUSE CHECK REPLACEMENT SCRUBTEC 5458 545BL 5538 553BL BOOST 5 6538 653BL 651BCL 661BL 81 FUSE CHECK REPLACEMENT SCRUBTEC 545E 553 653 ener seer nnne 82 BRUSH MOTOR ELECTROMAGNETIC SWITCH DISASSEMBLY ASSEMBLY SCRUBTEC 5458 545BL 5538 553BL BOOST 5 6538 653BL 651BCL 661BL 83 DRIVE SYSTEM ELECTRONIC BOARD DISASSEMBLY ASSEMBLY SCRUBTEC 545BL 553BL BOOST 5 653BL 651BCL 661 1 85 FUNCTION ELECTRONIC BOARD DISASSEMBLY ASSEMBLY SCRUBTEC 5458 5
4. 1 058 5 mm 760 mm 1 228 mm 540 8 mm DIMENSIONS SCRUBTEC 553BL 1 058 5 mm 1 228 mm 540 8 mm SCRUBTEC 5458 545BL 5538 553BL BOOST 5 12 653B 65381 651BCL 661BL 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ENGLISH MAINTENANCE DIMENSIONS SCRUBTEC BOOST 5 1 058 5 mm 760 mm LJ o c 540 8 DIMENSIONS SCRUBTEC 653B 1 088 mm 760 mm 1 323 mm 541 mm SCRUBTEC 545B 545BL 553B 553BL BOOST 5 6538 653BL 651BCL 661BL 545E 553E 653E MAINTENANCE DIMENSIONS SCRUBTEC 653BL
5. DRIVE SYSTEM DRIVE SYSTEM MOTOR DIFFERENTIAL DISASSEMBLY ASSEMBLY SCRUBTEC 545BL 553BL BOOST 5 653BL 651BCL 661BL Disassembly 1 If the tank 21 and or 20 contains recovery water Drive the machine to the appointed disposal area the ignition key 80 to 0 Empty the recovery water tank 21 with the hose 16 Empty the solution clean water tank 20 with the hose 17 2 Remove the squeegee see the procedure in the relevant paragraph 3 Remove the batteries see the procedure in the relevant paragraph 4 Prepare an hoisting system A on which the machine is to be laid on one side Place a panel B on the hoisting system to avoid damaging the machine 5 With the help of an assistant tilt the machine on one side and lay it on the panel B 6 Remove the screws C then remove the wheels D and recover the keys E 7 Remove the screws F on both sides 8 Disconnect the connectors of the drive system motor 9 f necessary remove the spacers I and the retaining rings 10 Remove the motor differential J Assembly 11 Assemble in the reverse order of disassembly C PN X ntl P100155 9097062000 2 2009 06 SCRUBTEC 545B 54581 5538 553BL BOOST 5 73 6538 653BL 651BCL 661BL 545 553E 653E DRIVE SYSTEM TROUBLESHOOTING Open circuit Possible causes 1 There are bulky debris or cords under the machine or arou
6. The hole allowing to compensate the air in the cover air gap contributes to create vacuum in the tank 8 Close the cover NOTE Figure showing 653BL P100119 SCRUBTEC 545B 545BL 5538 553BL BOOST 5 58 653B 653BL 651BCL 66181 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL RECOVERY WATER SYSTEM SQUEEGEE CLEANING CHECK REPLACEMENT AND SQUEEGEE BLADE REPLACEMENT models CAUTION It is advisable to wear protective gloves when cleaning the squeegee because there may be sharp debris Disassembly and cleaning 1 Drive the machine on a level floor 2 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 653B 653BL 651BCL 661BL Turn the ignition key 80 to 0 SCRUBTEC 545E 553E 653E Disconnect the power supply cable 59 from the electrical mains Lower the squeegee 25 with the lever 10 Loosen the handwheels 26 and remove the squeegee 25 Disconnect the vacuum hose 15 from the squeegee Clean the steel squeegee Fig 1 or the aluminium squeegee Fig 2 Clean the compartments A Fig 1 or 2 and the hole B especially Check the front blade C and the rear blade D for integrity cuts and tears if necessary replace them see the procedure in the following paragraph 7 Install the squeegee in the reverse order of removal Check and replacement 1 Clean the steel squeegee Fig 1 or the aluminium squeegee Fig 2 as shown in the previous p
7. Carefully remove the batteries B ssembly Assemble the batteries in the reverse order of disassembly referring to the installation diagram C and note the following Set the machine according to the type of batteries installed WET or GEL as shown in the relevant paragraph 5301566 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 78 653B 653BL 651BCL 66181 545 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM BATTERY TYPE SETTING WET OR GEL SCRUBTEC 545B 553B 653B Set the electronic board of the machine and of the battery charger if equipped according to the type of batteries installed WET or GEL according to the following procedure Machine setting 1 Press the switch 71 or 73 and pay attention to the following in the very first seconds of machine operation Ifthe green warning light 81a is flashing the machine is set to GEL the red warning light 81c is flashing the machine is set to WET If the setting is to be changed perform the following procedure Make sure that the switches 71 and 73 are turned off Press and hold the switches 71 and 73 at the same time Release the switches 71 and 73 at least 8 seconds after starting the machine Within three seconds press the switch 73 again for a few seconds and check that the warning light for the required setting is flashing as shown in step 1 DRON Battery charger setting i
8. and L and remove four carbon brush supports J If necessary disconnect the electrical connections M 10 Check the carbon brushes for wear Replace the carbon brushes when the contact with the motor armature is insufficient the carbon brushes are worn the carbon brush contact surface is not integral the thrust spring is broken etc 11 If necessary disconnect the connections O and remove the carbon brushes with their supports J and replace them Replace the carbon brushes as an assembly Reset 12 Assemble the components in the reverse order of disassembly and note the following When connecting the terminals O take care of their insulation from the surrounding parts of the frame 5301541 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 46 653B 653BL 651BCL 66181 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ENGLISH BRUSHING SYSTEM BRUSH MOTOR CARBON BRUSH CHECK REPLACEMENT SCRUBTEC 651BCL Check 1 Remove the brush motor see the procedure in the relevant paragraph 2 At the workbench remove dust and debris from the motor especially in the area of the protection clamp 3 Remove the protection clamp A 4 For each carbon brush move the protection B and remove the screws C 5 Remove the carbon brushes D 6 Check carbon brushes D for wear Replace the carbon brushes when the contact with the motor armature is insufficient the carbon b
9. 653E 9097062000 2 2009 06 SERVICE MANUAL SOLUTION CLEAN WATER SUPPLY SYSTEM SOLENOID VALVE DISASSEMBLY ASSEMBLY SCRUBTEC 653B 653BL 651BCL 661BL 653E Disassembly 1 For machines with brushes pad holders Remove the brushes pad holders 2 Lower the deck by pressing the pedal 11 3 Loosen the clamp A and disconnect the hoses B from the filter assembly C 4 Disconnect the union D from the solenoid valve E and recover the gasket 5 Remove the screw F disconnect the connector G and recover the gasket 6 Remove the nuts 7 Remove the solenoid valve E with the hoses B If necessary separate the hoses B from the solenoid valve and disconnect it from the union Assembly 8 Assemble in the reverse order of disassembly QA S301523A SCRUBTEC 5458 545BL 553B 553BL BOOST 5 kaki 653B 653BL 651BCL 661BL 545E 553E 653E zi ENGLISH SERVICE MANUAL SOLUTION CLEAN WATER SUPPLY SYSTEM TROUBLESHOOTING Small amount of solution or no solution reaches the brush Possible causes 1 2 3 4 5 The solution clean water filter is clogged dirty clean The solution clean water tap is stuck closed replace The solenoid valve is broken or there is an open in the electrical connection replace the solenoid valve repair the electrical connection There is debris in the solution tank clogging the output hole clean th
10. 82b 82c 82a 77 78 84 SCRUBTEC 545BL 553BL BOOST 5 P100102 P100103 P100104 SCRUBTEC 545B 545BL 5538 553BL BOOST 5 20 653B 653BL 651BCL 66181 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ENGLISH MAINTENANCE MACHINE NOMENCLATURE SCRUBTEC 653B 653BL 651BCL 661BL Throughout this Manual you will find numbers in brackets for example 2 These numbers refer to the components indicated in these two nomenclature pages Refer to these pages whenever it is required to identify a component mentioned in the text 1 Control panel 51 Detergent pump holder 2 Handlebar 52 Batteries 3 Brush forward gear switch Brush switch 53 Battery caps 4 Drive speed adjuster 54 Solution clean water filter 5 Battery charger data inspection window optional 55 Solution clean water tap 6 Battery charger cable optional 56 Reference table for detergent proportioning 7 Battery charger cable holder optional 57 Battery connection diagram 8 Recovery water drain hose plug 71 Brush pad holder switch 9 Reverse gear switch 72 Brush pad holder switch warning light 10 Squeegee lifting lowering lever 73 Vacuum system switch 11 Deck lifting lowering pedal 74 Vacuum system switch warning light 11a Pedal position when deck is lifted 75 Brush pad holder release switch 11b Pedal position when deck is lowered 76 Brush pad holder release switch warning light 11c Extra pressure activati
11. SCRUBTEC 545BL 553BL BOOST 5 653BL 651BCL 661BL Turn the ignition key 80 to 0 SCRUBTEC 545E 553E 653E Disconnect the power supply cable 59 from the electrical mains Clean the tank 20 with clean water Start the machine as shown in the User Manual and keep it running until the solution clean water tank is completely empty Clean the solution filter see the following procedure SOLUTION FILTER CLEANING SCRUBTEC 545B 545BL 553B 553BL BOOST 5 545E 553E 1 2 3 4 5 Drive the machine on a level floor SCRUBTEC 545BL 553BL BOOST 5 Turn the ignition key 80 to 0 SCRUBTEC 545E 553E Disconnect the power supply cable 59 from the electrical mains Close the solution tap A under the machine left lower side The tap A is closed when it is in the position B and it is open when it is in the position C Remove the transparent cover D then remove the filter strainer E Clean and install them on the support F NOTE 9 The filter strainer E must be correctly positioned on the housing of the support Open the tap A P100109 SCRUBTEC 545B 545BL 5538 553BL BOOST 5 28 653B 653BL 651BCL 66181 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL SOLUTION CLEAN WATER SUPPLY SYSTEM SOLUTION FILTER CLEANING SCRUBTEC 653B 653BL 651BCL 661BL 653E 1 Drive the machine on a level flo
12. Solution filter 55 Solution tap 56 Solenoid valve 59 Power supply cable 60 Power supply cable holder 61 Recovery water tank retaining plate 62 Brush pad holder switch 63 Vacuum system switch 64 Counterweight 79 Hour counter optional 82 Washing water flow control switches 82a Flow increase switch 82b Flow decrease switch 82c Washing water flow indicator SCRUBTEC 5458 545BL 5538 553BL BOOST 5 26 653B 653BL 651BCL 66181 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ENGLISH MAINTENANCE MACHINE NOMENCLATURE SCRUBTEC 653E Continues S se G A 224 e ps 0 S ZED Dis 5100146 5458 545BL 5538 553BL BOOST 5 200806 6538 65381 651BCL 661BL 545E 553E 653E ENGLISH SERVICE MANUAL SOLUTION CLEAN WATER SUPPLY SYSTEM SOLUTION CLEAN WATER SUPPLY SYSTEM SOLUTION CLEAN WATER TANK AND SUPPLY SYSTEM CLEANING All models 1 2 Drive the machine to the appointed solution disposal area Turn the ignition key 80 to 0 SCRUBTEC 545E 553E 653E Disconnect the power supply cable 59 from the electrical mains Empty the solution clean water tank 20 with the hose 17 Start the machine as shown in the User Manual and keep it running until the solution clean water tank is completely empty
13. 12 Check the carbon brushes N for wear Replace the carbon brushes when the contact with the motor armature is insufficient the carbon brushes are worn the carbon brush contact surface is not integral the thrust spring is broken etc 13 If necessary disconnect the connections O and remove the carbon brushes with their supports J and replace them Replace the carbon brushes as an assembly SE LO po Reset 12 Assemble the components in the reverse order of disassembly and note the following When connecting the terminals O take care of their insulation from the surrounding parts of the frame 301539 5 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 909706290812 2009 06 6538 653BL 651BCL 661BL 545 553E 653E s ENGLISH SERVICE MANUAL BRUSHING SYSTEM BRUSH MOTOR CARBON BRUSH CHECK REPLACEMENT SCRUBTEC 653B 653BL Check 1 If the tank 21 contains recovery water Drive the machine to the appointed recovery water disposal area Tur the ignition key 80 to 0 Empty the recovery water tank 21 with the hose 16 2 Drive the machine on a level floor 3 Remove the brush pad holder 4 Lower the deck by pressing the pedal 11 5 Turn the ignition key 80 to 0 Carefully lift the tank 40 7 Disconnect the battery connector 12 8 Remove dust and dirt from the motor carbon brush support area A 9 Disengage the fasteners
14. 59 5 mm Weight with empty tanks 131 kg 138 kg Maximum weight with full tanks 173 kg 195 kg Brush motor power 1 100 W 50 60 Hz Brush speed 150 rpm Brush pressure 28 3 kg 30 kg Machine test have been performed under the following conditions Battery maximum size Brush and squeegee maximum size Full clean water tank Optional equipment installed Wheel weight checked Each wheel print checked on cement Result expressed as maximum value for both front and rear wheels 10 SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ENGLISH DIMENSIONS SCRUBTEC 545B MAINTENANCE E L 2 L 9 iS 1 190 760 mm E on CN in DIMENSIONS SCRUBTEC 545BL E E a L O 1 190 760 mm E E CN in SCRUBTEC 5458 5458 5538 55381 BOOST 5 11 9097062000 2 2009 06 6538 653BL 651BCL 661BL 545 553E 653E MAINTENANCE DIMENSIONS SCRUBTEC 553B
15. Auxiliary signal power supply OUT 24V always with connected batteries SW1 SW2 4 Hour counter power supply OUT OV with Vacuum function activated HM 5 ai OUT 24V with key EB2 J1 15 6 Return from ignition key IN 24V with key on K1 7 a 8 Electronic board power supply IN OV always with connected batteries BAT 9 Brush fuse voltage drop reading IN 0 50mV nearly proportional to the current in brush motors F1 10 Brush fuse voltage drop reading IN OV always with connected batteries F1 11 switch power OUT ov with brush function activated ES1 12 Vacuum system relay power supply OUT OV with Vacuum function activated ES2 13 7 Switehirelay power OUT 24V with key on I ES1 ES2 14 Brush motor braking circuit IN 24V with brush function deactivated ES1 NC 15 Drive system brush enabling panel IN 24V with pressed paddle Sw1 16 9097062000 2 2009 06 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 6538 653BL 651BCL 661BL 545E 553E 653E 97 ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM EB1 ELECTRONIC BOARD CONNECTOR PINS SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL continues J2 MOLEX MINIFIT type 2 ways vertical Electronic PIN Description board V ref Connected to in out 1 Solenoid valve power supply OUT 24V with key on EV1 OV pulsed according to water flow setting only with paddle 2 Solenoid Valve po
16. D YE GN d FLI SWI BU 0 7 BN D 96 mah RON BN D EBL YE CN BG L g YE GN SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 65381 651BCL 661BL 545 553E 653E FR P100126 9097062000 2 2009 06 SERVICE MANUAL ENGLISH J1 13 14 15 16 Electronic board for 545B 553B 653B ELECTRICAL SYSTEM EB1 ELECTRONIC BOARD CONNECTOR PINS SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL J2 J3 J5 1 112 3 2 415 6 3 2 Electronic board for Scrubtec Supplier Ref Ref Rev Spec 7CFBA600 Till S N 072115094 7CFBA606 current version 545BL 553BL BOOST 5 653BL 651BCL 661BL Supplier Ref Ref Rev Spec 7CFBA700 Till S N 072014255 7CFBA702 current version CONNECTORS on B side card J1 MOLEX MINIFIT type 16 ways vertical S301581 Electronic PIN Description board V ref Connected to in out 1 Electronic board power supply BOARD 24 always with connected batteries BAT 2 Ignition key circuit power supply IN OUT 24V always with connected batteries K1 3
17. F2 Vacuum system fuse F4 Signal circuit fuse F5 Brush release fuse F6 Pump fuse HM Hour counter optional K1 Ignition key M1 Brush pad holder motor M2 Vacuum system motor M5 Detergent pump optional RV3 Detergent potentiometer optional EV1 SW1 Brush drive system enabling switch NOTE Figure showing 545B P100147 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 90 6538 653BL 651BCL 661BL 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM WIRING DIAGRAM SCRUBTEC 545B 553B 653B Key Colour codes BAT 24 V battery BK Black C1 Battery connector BU 2 Battery charger connector BN Brown CH Battery charger optional GN CS Deck connector EB1 Function electronic board OG ES1 Brush electromagnetic switches PK Pink ES2 Vacuum system relay RD EV1 Water solenoid valve VT Violet F1 Deck fuse White F2 Vacuum system fuse YE Yellow F4 Signal circuit fuse F5 Brush release fuse F6 Pump fuse HM Hour counter optional K1 Ignition key M1 Brush pad holder motor M2 Vacuum system motor M5 Detergent pump optional RV3 Detergent 96 potentiometer
18. N www hilfisk alto com SCRUBTEC 545B 545BL 5538 553BL BOOST 5 6538 653BL 651BCL 661BL 545E 553E 653E Nilfisk ALTO Why Compromise ENGLISH SERVICE MANUAL 9097062000 2 2009 06 SERVICE MANUAL ENGLISH GENERAL INFORMATION k ki kk de n Ya e a n a n n e rat n e n n a e a A Ek m n K n ak n ENERO 3 GONVENTION cc 3 MACHINE Bid em 3 MACHINE TRANSPORTATION Er 3 OTHER REFERENCE 15 3 SAFETY C T ete 4 4 GENERAL ANSTRUCTION S be DU ee 4 TECHNICAL DATA SCRUBTEC 5458 545BL 5538 553BL 5 5 7 TECHNICAL DATA SCRUBTEC 6538 653BL 651BCL 6618 8 TECHNICAL DATA SCRUBTEC 545E 553E 653 10 MACHINE DIMENSION eee 11 MAINTENANGE 22 22 17 SCHEDULED MAINTENANCE TABLE SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL 17 SCHEDULED MAINTENANCE TABLE SCRUBTEC 545E 553E 653 sse eene enne 17 MACHINE NOMENCLATURE SCRUBTEC 5458 545BL 5
19. Remove the reduction unit D with the relevant wiring harness Recover the key E If necessary remove the solution hose E If necessary remove the motor wiring harness G ssembly Assemble in the reverse order of disassembly NOTE Figure showing 653E 54 SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL 545 553E 653E 5301547 9097062000 2 2009 06 SERVICE MANUAL BRUSHING SYSTEM CHECK REPLACEMENT ADJUSTMENT OF DRIVING BELTS BETWEEN MOTORS AND CYLINDRICAL BRUSHES SCRUBTEC 651BCL Check Drive the machine on a level floor Turn the ignition key 12 to 0 Lower the cylindrical brush deck by pressing the pedal 11 Remove the screws A and remove the covers B Visually inspect the belt C for integrity cuts tears or cracks if necessary replace it according to the following procedure Check the tension of the belt C according to the following procedure eplacement If the belt G is to be replaced loosen the nut D and move the pulley K to loosen the belt Tension the belt according to the following procedure elt tensioning Check the tension of the belt C between motor and brush The tension is correct When pressing the belt in its centre with a force of 22 Ib 10 kg F the belt bends for 0 20 in 5 mm If necessary tension the belt according to the following procedure Loosen the nut D and adjust
20. broken replace 2 one way valve is broken replace There is water in the detergent tank Possible causes 1 The one way valve is broken replace 5301568 SCRUBTEC 5458 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL 545 553 653E 93 ENGLISH SERVICE MANUAL BRUSHING SYSTEM BRUSHING SYSTEM BRUSH PAD CLEANING WARNING AN It is advisable to wear protective gloves when cleaning the brushes pads because there may be sharp debris Remove the brushes pads as shown in the User Manual Clean and wash the brushes pads with water and detergent Check the brushes pads for integrity and wear if necessary replace them SCRUBTEC 651BCL Remove the debris container A by pulling it on one side with the handle B Empty and wash the debris container A and then install it by engaging it on the inside fasteners Bom 6 5000000 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 34 6538 653BL 651BCL 661BL 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL BRUSHING SYSTEM BRUSH PAD HOLDER DECK OR CYLINDRICAL BRUSH DECK DISASSEMBLY ASSEMBLY SCRUBTEC 545B 545BL 553B 553BL BOOST 5 The machine can be equipped with either the brush pad holder deck or the cylindrical brush deck Disassembly 1 Drive the machine on a level floor 2 Remove the brushes pad holders as shown in the User Manual 3 Lower the brush pad holder deck by press
21. hole A loosen the threaded dowel and remove the maximum speed adjuster knob B 3 Remove the adhesive C 4 Remove the screws D and move the cover E 5 Unscrew the potentiometer mounting nut 6 Disconnect the potentiometer connector 7 Remove the potentiometer A 8 ssembly Assemble the components in the reverse order of disassembly and note the following Fasten the knob B with the potentiometer shaft L completely turned counter clockwise and the hole A in the lower centre part of the panel as shown in the figure 9 Test the drive system and the maximum speed change P100154 SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL 545 553 653E 92 ENGLISH SERVICE MANUAL DRIVE SYSTEM DRIVE SYSTEM MOTOR ELECTRICAL INPUT CHECK SCRUBTEC 545BL 553BL BOOST 5 653BL 651BCL 661BL WARNING AN This procedure must be performed by qualified personnel only and with the help of an assistant Check that the batteries are completely charged otherwise charge them as shown in the User Manual If the tank 21 contains recovery water Drive the machine to the appointed recovery water disposal area the ignition key 80 to 0 Empty the recovery water tank 21 with the hose 16 Drive the machine on a level floor Lower the deck by pressing the pedal 11 Under the left side the machine install a suitable jack C
22. in the position A and slightly lift the machine so that the left wheel C can turn freely without touching the floor or the jack WARNING While performing this procedure pay attention to the rotation of the driving wheel C 10 Apply the amperometric pliers D on one cable E of the drive system motor Turn the ignition key 80 to 47 Turn the speed adjuster 84 to the maximum speed With the help of an assistant who firmly keeps the machine by the handlebar press one of the switches 83 and check that the electrical input is 1 5 2 5 A at 24 V Release the switches 83 Turn the ignition key 80 to 0 and remove the amperometric pliers D If the electrical input is higher perform the following procedures to detect and correct the abnormal input e Check if there is dust or debris preventing the component rotation The lifted wheel must turn freely whit a slight resistance of the differential e If necessary disassemble the motor differential see the procedure the relevant paragraph then check for hub correct alignment and bearing smooth running If the above mentioned procedures do not lead to a correct electrical input the motor must be replaced see the procedure in the relevant paragraph Perform steps 4 and 5 in the reverse order SCRUBTEC 545B 545BL 553B 553BL BOOST 5 70 653B 65381 651BCL 661BL 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ENGLISH
23. it JAPAN Nilfisk Advance Inc 1 6 6 Kita shinyokohama Kouhoku ku Yokohama 223 0059 Japan Tel 81 45 548 2571 Fax 81 45 548 2541 MALAYSIA Nilfisk Advance Sdn Bhd Sd 14 Jalan KIP 11 Taman Perindustrian KIP Sri Damansara 52200 Kuala Lumpur Malaysia Tel 60 3 603 6275 3120 Fax 60 3 603 6274 6318 NORWAY Nilfisk Advance AS Bjernerudveien 24 1266 Oslo Norway Tel 47 22 75 17 70 Fax 47 22 75 17 71 E mail info nilfisk alto no www nilfisk alto no PEOPLE S REPUBLIC OF CHINA Nilfisk Advance Shenzhen Ltd Blok 3 Unit 130 1001 Honghua Road Int Commercial amp Trade Center Fuitian Free Trade Zone 518038 Shenzhen P R China Tel 86 755 8359 7937 Fax 86 755 8359 1063 POLAND Nilfisk Advance Sp Z O O 05 800 Pruszk w ul 3 go MAJA 8 Poland Tel 48 22 738 37 50 Fax 48 22 738 37 51 info gnilfisk alto pl www nilfisk alto pl PORTUGAL Nilfisk ALTO Division of Nilfisk Advance Lda Sintra Business Park Zona Industrial Da Abrunheira Edificio 1 10 A P 2710 089 Sintra Tel 35 808 200 537 Fax 35 121 911 2679 E mail mkt nilfisk advance es www nilfisk alto com RUSSIA Nilfisk Advance LLC 127015 Moskow Vyatskaya str 27 bld 7 Russia Tel 7 495 783 96 02 Fax 7 495 783 96 03 E mail info nilfisk advance ru SINGAPORE Nilfisk Advance Pte Ltd Nilfisk ALTO Division 40 Loyang Drive Singapore 508961 sales nilfisk advance c
24. on slopes with a gradient exceeding the specifications A Do not use the machine in particularly dusty areas While using this machine take care not to cause damage to people or objects Do not bump into shelves or scaffoldings especially where there is a risk of falling objects Do not put any can containing fluids on the machine machine working temperature must be between 32 F and 104 F 0 C and 40 C machine storage temperature must be between 32 F and 104 F 0 C and 40 humidity must be between 30 and 95 When using floor cleaning detergents follow the instructions on the labels of the detergent bottles Tohandle floor cleaning detergents wear suitable gloves and protections Do not use the machine as a means of transport Do not allow the brushes to operate while the machine is stationary to avoid damaging the floor case of fire use a powder fire extinguisher not a water one Do not tamper with the machine safety guards and follow the ordinary maintenance instructions scrupulously Do not allow any object to enter into the openings Do not use the machine if the openings are clogged Always keep the openings free from dust hairs and any other foreign material which could reduce the air flow Do not remove or modify the plates affixed to the machine This machine cannot be used on roads or public streets attenti
25. relevant paragraph If the above mentioned procedures do not lead to a correct electrical input the motor must be replaced see the procedure in the relevant paragraph Reset 11 Perform steps 3 to 7 in the reverse order 9097062000 2 2009 06 SCRUBTEC 545B 545BL 553B 553BL BOOST 5 43 6538 653BL 651BCL 661BL 545 553E 653E ENGLISH SERVICE MANUAL BRUSHING SYSTEM BRUSH MOTOR ELECTRICAL INPUT CHECK SCRUBTEC 545E 553E 653E Continues 44 SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL 545E 553E 653E AA S 7 B 9 P100152 9097062000 2 2009 06 SERVICE MANUAL BRUSHING SYSTEM BRUSH MOTOR CARBON BRUSH CHECK REPLACEMENT SCRUBTEC 545B 545BL 553B 553BL Check 1 If the tank 21 contains recovery water Drive the machine to the appointed recovery water disposal area the ignition key 80 to 0 Empty the recovery water tank 21 with the hose 16 Drive the machine on a level floor Remove the brush pad holder Lower the deck by pressing the pedal 11 Turn the ignition key 80 to 0 Carefully lift the tank 40 Disconnect the battery connector 12 0 Remove dust and dirt from the motor carbon brush support area A 1 Disengage the fasteners K and L and remove four carbon brush supports J If necessary disconnect the electrical connections M
26. the brush pad holder deck see the procedure in the relevant paragraph 2 Atthe workbench remove the screw A from the deck 3 Remove the hub assembly B with a puller 4 Remove the screws C 5 Remove the reduction unit D 6 If necessary remove the water distribution union E and flange F from the reduction unit A T ssembly Assemble in the reverse order of disassembly 5301544 SCRUBTEC 5458 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL 545E 553E 653E sa SERVICE MANUAL BRUSHING SYSTEM BOOST DECK MOTOR DISASSEMBLY ASSEMBLY SCRUBTEC BOOST 5 Disassembly 1 Remove the Boost deck see the procedure in the relevant paragraph 2 At the workbench remove the nuts and remove the flex plates B 3 Remove the screw C and remove the plate driver D 4 Keep the retainer eccentric the pin roll the chiel boost bearing wachers and eccentric E 5 Remove the screws F 6 A T Remove the reduction motor G keeping the key H ssembly Assemble the components in the reverse order of disassembly and note the following e Tighten the screws and the screw C at 10 32 Ibf ft 14 1 42 kgf m Tighten the nuts A at 8 10 8 1 10 kgf m SCRUBTEC 545B 545BL 5538 553BL BOOST 5 50 653B 653BL 651BCL 66181 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL BRUSHING SYST
27. the position of the pulley E When tensioning procedure has been performed tighten the nut D 11 Repeat step 8 Reset 12 Perform steps 3 and 4 in the reverse order a SCRUBTEC 545B 545BL 5538 55381 BOOST 5 ki s t ak 06 653B 653BL 651BCL 661BL 545E 553E 653E 99 SERVICE MANUAL BRUSHING SYSTEM CHECK REPLACEMENT ADJUSTMENT OF DRIVING BELTS BETWEEN MOTORS AND CYLINDRICAL BRUSHES SCRUBTEC 651BCL Continues 5301548 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 56 653B 653BL 651BCL 66181 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL BRUSHING SYSTEM TROUBLESHOOTING All brushes do not turn Possible causes The brush enabling microswitch is misadjusted or broken adjust or replace The wiring harness between microswitch and function electronic board is damaged repair The brush motor electromagnetic switch wiring harness is damaged repair The function electronic board is damaged replace The wiring harness between function electronic board and brush motor electromagnetic switch is damaged repair The brush motor electromagnetic switch is damaged replace The brush motor fuse is open replace NOaRWN gt One brush does not turn For models with two brushes Possible causes 1 The motor carbon brushes are worn replace 2 Bulky debris or cords around the brushes or between the brushes and its flange remove
28. 45BL 5538 553BL BOOST 5 6538 653BL 651BCL 661 87 WATER FLOW CONTROL ELECTRONIC BOARD DISASSEMBLY ASSEMBLY SCRUBTEC 545E 553E 653 88 TROUBLESHOO TIN cm 89 COMPONENT LAYOUT SCRUBTEC 5458 5538 6538 90 WIRING DIAGRAM SCRUBTEC 5458 5538 6538 91 COMPONENT LAYOUT SCRUBTEC 54581 55381 BOOST 5 65381 651BCL 661BL sse 92 WIRING DIAGRAM SCRUBTEC 545BL 553BL BOOST 5 653BL 651BCL 661 01 94 COMPONENT LAYOUT SCRUBTEC 545E 553E 6536 95 WIRING DIAGRAM SCRUBTEC 545E 553E 6536 96 EB1 ELECTRONIC BOARD CONNECTOR PINS SCRUBTEC 5458 545BL 5538 553BL BOOST 5 6538 653BL 651BCL 661 1 97 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 2 653B 653BL 651BCL 661BL 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ENGLISH GENERAL INFORMATION GENERAL INFORMATION 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 MACHINE LIFTING WARNING Do not work under the lifted machine without supporting it with safety stands MACHINE TRANSPORTATION WARNING Before transporting the machine make sure th
29. 5 Install the squeegee 25 and screw down the handwheels 26 6 If necessary adjust the squeegee balance adjusting handwheel 27 9097062000 2 2009 06 SCRUBTEC 545B 54581 5538 553BL BOOST 5 59 6538 653BL 651BCL 661BL 545 553E 653E ENGLISH SERVICE MANUAL RECOVERY WATER SYSTEM SQUEEGEE CLEANING CHECK REPLACEMENT AND SQUEEGEE BLADE REPLACEMENT models Continues Fig 2 5301552 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 60 653B 653BL 651BCL 66181 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL RECOVERY WATER SYSTEM VACUUM SYSTEM MOTOR FILTER CLEANING All models Disassembly and cleaning 1 Ifthe tank 21 contains recovery water 2 Drive the machine to the appointed recovery water disposal area 3 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 6538 653BL 651BCL 661BL Turn the ignition key 80 to 0 SCRUBTEC 545E 553E 653E Disconnect the power supply cable 59 from the electrical mains Empty the recovery water tank 21 with the hose 16 4 Drive the machine on a level floor 5 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 6538 653BL 651BCL 661BL Turn the ignition key 80 to 0 SCRUBTEC 545E 553E 653E Disconnect the power supply cable 59 from the electrical mains 6 SCRUBTEC 545E 553E 653E Open the recovery water tank cover 22 Remove the retaining plate 61 of the tank 40 7 Carefully lift the tank 40 8 Remov
30. 538 553BL BOOST 5 18 MACHINE NOMENCLATURE SCRUBTEC 6538 653BL 651BCL 661 1 21 MACHINE NOMENCLATURE SCRUBTEC 545E 553 24 MACHINE NOMENCLATURE SCRUBTEC 653E sss eene nnns 26 SOLUTION CLEAN WATER SUPPLY SYSTEM 1 1 RR AR RR RAN NR REN R RR SAN RR RAN R4 nannan 28 SOLUTION CLEAN WATER TANK AND SUPPLY SYSTEM CLEANING All 28 SOLUTION FILTER CLEANING SCRUBTEC 5458 545BL 5538 553BL BOOST 5 545E 553 28 SOLUTION FILTER CLEANING SCRUBTEC 6538 653BL 651BCL 661BL 653 29 SOLENOID VALVE DISASSEMBLY ASSEMBLY 5458 545BL 5538 553BL BOOST 5 545E 553 30 SOLENOID VALVE DISASSEMBLY ASSEMBLY SCRUBTEC 6538 653BL 651BCL 661BL 653 31 TROUBLESHOOTING m 32 CHEMICAL MIXING SYSTEM aie 525 cu Pu xx EON 33 uei BieeeceeE E EMT 33 BRUSHING SYSTEM iii k kk genda ner ra dada o nva d Eran xxx va dad cese kan anas kr rana CE ce aua vean dans cu E En kaa kk S 34 BRUSH PAD
31. 553BL BOOST 5 9 6538 653BL 651BCL 661BL 545E 553E 653E ENGLISH SERVICE MANUAL GENERAL INFORMATION TECHNICAL DATA SCRUBTEC 545E 553E 653E Model SCRUBTEC 545E SCRUBTEC 553E SCRUBTEC 653E 1 brush pad holder 1 brush pad holder 1 brush pad holder Power supply 230 V 50 60 Hz Machine height 1 058 5 mm 1 088 mm Solution tank capacity 42 litres 55 litres Recovery water tank capacity 42 litres 55 litres Min max solution flow 0 1 6 It min Solution clean water autonomy 0 29 gal min Media Average 36 min 52 min Front wheel diameter 200 mm 250 mm Front and rear wheel specific pressure on the floor 0 7 N mm 3 2 N mm 1 N mm 1 2 N mm Rear wheel diameter 100 mm Minimum turning radius 600 mm 650 mm 700 mm Vacuum system motor power 550 W 50 60 Hz Gradeability 2 1 ESOL e position 68 dB A 3dB A SO 3744 ISO 4871 ERA dB A Vibration level at the operator s arms ISO 5349 1 lt 2 5 m s Total consumption in work condition 6 A 50Hz 7 A 60Hz Vacuum system circuit capacity 1 316 mm Cleaning width 450 mm 530 mm Squeegee width 760 mm Machine maximum length 1 147 mm 1 185 mm 1 306 mm Machine width without squeegee 512 mm 541 mm Brush diameter 450 mm 530 mm Deck right left offset 37 1 mm 75 9 mm 77 mm Brush distance from the ground when lifted 60 1 mm
32. 62000 2 2009 06 22 653B 653BL 651BCL 661BL 545 553E 653E SERVICE MANUAL MAINTENANCE MACHINE NOMENCLATURE SCRUBTEC 653B 653BL 651BCL 66181 Continues 71 72 74 73 76 75 79 80 82b 82c 82 77 78 84 SCRUBTEC 653BL 653BCL 661BL P100116 P100117 P100104 SCRUBTEC 5458 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL 545 553 653E 23 MAINTENANCE MACHINE NOMENCLATURE SCRUBTEC 545E 553E Throughout this Manual you will find numbers in brackets for example 2 These numbers refer to the components indicated in these two nomenclature pages Refer to these pages whenever it is required to identify a component mentioned in the text 1 Control panel 2 Handlebar 6 Brush pad holder switches 10 Squeegee lifting lowering lever 11 Deck lifting lowering pedal 11a Pedal position when deck is lifted 11b Pedal position when deck is lowered 13 Rear steering wheels 14 Front wheels on fixed axle 15 Squeegee vacuum hose 16 Recovery water drain hose 17 Solution drain and level check hose 18 Brush pad holder deck 19 Brush pad holder with pad 20 Solution tank 21 Recovery water tank 22 Recovery water tank cover 23 Can holder 25 Squeegee 26 Squeegee mounting handwheels 27 Squeegee balance adjusting handwheel 28 Machine straight forward movement adjusting handwheel 29 Machine forward speed adjusting handwheel 30 Recovery water tank co
33. BL 5538 553BL BOOST 5 6538 653BL 651BCL 661BL Turn the ignition key 80 to 0 SCRUBTEC 545E 553E 653E Disconnect the power supply cable 59 from the electrical mains SCRUBTEC 545E 553E 653E Open the recovery water tank cover 22 Remove the retaining plate 61 of the tank 40 Carefully lift the tank 40 Check Tightening of mounting screws and nuts Correct position of fasteners Visible faults in the components Leaks of fluids 7 Carefully lower the tank 40 8 SCRUBTEC 545E 553E 653E Install the retaining plate 61 oun WARNING SCRUBTEC 545E 553E 653E When the maintenance repair procedure is completed the tank 40 must always be locked with the plate 61 9 Remove the machine from the hoisting system SCRUBTEC 5458 545BL 5538 553BL BOOST 5 76 653B 653BL 651BCL 661BL 545 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM ELECTRICAL SYSTEM MACHINE WORKING HOUR CHECK SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL equipped with optional hour counter 1 the ignition key 80 to I 2 Press the vacuum system switch 73 and read on the hour counter 79 the total number of working hours scrubbing drying performed by the machine 3 Turn off the vacuum system by pressing the switch 73 4 the ignition key 80 to 0 MACHINE WORKING HOUR CHECK SCRUBTEC 545E 553E 653E equipped
34. DRIVE SYSTEM DRIVE SYSTEM MOTOR ELECTRICAL INPUT CHECK SCRUBTEC 545BL 553BL BOOST 5 653BL 651BCL 661BL Continues 5301562 SCRUBTEC 5458 545BL 553B 553BL BOOST 5 ak 6538 653BL 651BCL 661BL 545E 553E 653E a ENGLISH SERVICE MANUAL DRIVE SYSTEM DRIVE SYSTEM MOTOR CARBON BRUSH CHECK AND REPLACEMENT SCRUBTEC 545BL 553BL BOOST 5 653BL 651BCL 661BL 1 2 3 4 5 Drive the machine to the appointed disposal area and empty the recovery water tank 21 with the hose 16 Place the machine on a hoisting system if available Otherwise drive the machine on a level floor Turn the ignition key 80 to 0 Disconnect the battery connector 12 Operating on the left side of the machine clean the drive system motor B in the area of the covers A thus removing dirt and dust Unscrew the covers A and remove the carbon brushes C Check the carbon brushes C for wear Replace the carbon brushes when the contact with the motor armature is insufficient the carbon brushes are worn the carbon brush contact surface is not integral the thrust spring is broken etc If necessary replace the carbon brushes Replace the carbon brushes as an assembly Assemble in the reverse order of disassembly S301563A SCRUBTEC 5458 545BL 5538 55381 BOOST 5 72 653B 653BL 651BCL 661BL 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ENGLISH
35. EM BOOST DECK VIBRATION DAMPERS DISASSEMBLY REPLACEMENT SCRUBTEC BOOST 5 Remove the Boost deck see the procedure in the relevant paragraph At the workbench remove the nuts A and remove the flex plates B Keep the washers C Remove the vibration dampers D unscrewing them from the flex plates B Assembly the new vibration dampers as well as the flex plates and note the following e Tighten the nuts A at 8 Ibf ft 10 8 1 10 kgf m Remove the nuts E and remove the brush deck holder plate F Keep the washers G Remove the vibration dampers unscrewing them from the main plate l Assembly the new vibration dampers as well as the brush deck holder plate and note the following Tighten the nuts E at 8 Ibf ft 10 8 1 10 kgf m AUN 5 SCRUBTEC 5458 54581 5538 55381 BOOST 5 a 653B 653BL 651BCL 661BL 545E 553E 653E ENGLISH SERVICE MANUAL BRUSHING SYSTEM BRUSH MOTOR DISASSEMBLY ASSEMBLY SCRUBTEC 651BCL Disassembly 1 Remove the cylindrical brush deck see the procedure in the relevant paragraph 2 At the workbench remove the screw from the motor which has to be disassembled 3 Remove the case B 4 Loosen the nut C and move the pulley D to loosen the belt E 5 Remove the belt E 6 Remove the screws F 7 Remove the motor A 8 ssembly Assemble the components
36. K SCRUBTEC 661BL WARNING This procedure must be performed by qualified personnel only Check Remove the brushes as shown the User Manual Lower the deck by pressing the pedal 11 Disconnect the motor which does not have to be checked Apply the amperometric pliers A on one cable B of the brush motor C Turn the speed adjuster 84 to idle and turn the ignition key 80 to I Turn on the brushes by pressing the switch 71 and check that the motor electrical input is 2 4 A at 24 V Turn off the brushes by pressing the switch 71 Turn the ignition key 80 to 0 Remove the amperometric pliers A If the electrical input is higher perform the following procedures to detect and correct the abnormal input a If the electrical input is higher than the maximum allowed value the 3 battery warning lights 81 flash simultaneously e Check the tightening of F1 fuse screw see the procedure in Fuse Check Replacement paragraph e Check if there is dust or dirt ropes cables etc on the brush hub e Check the motor carbon brushes see the procedure in the relevant paragraph Disassemble the motor see the procedure in the relevant paragraph and check the condition of all its components If the above mentioned procedures do not lead to a correct electrical input the motor must be replaced see the procedure in the relevant paragraph Reset 7 Perform steps 1 and 2 in the reverse
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38. TEC 5458 54581 5538 55381 BOOST 5 6538 653BL 651BCL 661BL 545E 553E 653E Bt ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM WATER FLOW CONTROL ELECTRONIC BOARD DISASSEMBLY ASSEMBLY SCRUBTEC 545E 553E 653E Disassembly 1 Disconnect the power supply cable 59 from the electrical mains but do not place it on the holder 60 2 If the power supply cable 59 is on the holder 60 remove it 3 Move aside the recovery water drain hose 16 4 Remove the screws A and carefully move the panel B 5 If necessary mark the position of the connections C of the water flow control electronic board D to reinstall them correctly if necessary refer to the wiring diagram to check the connection positions 6 Disconnect the connections C of the water flow control electronic board D 7 Remove the screws E then remove the water flow control electronic board D Assembly 8 Assemble in the reverse order of disassembly E E 0 is P100156 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 88 653B 653BL 651BCL 66181 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ELECTRICAL SYSTEM TROUBLESHOOTING See the previous chapters related to the use of the electrical system Other possible causes 1 batteries are discharged or the connections not efficient charge the batt
39. TEM BRUSH MOTOR ELECTRICAL INPUT CHECK SCRUBTEC 545B 545BL 553B 553BL BOOST 5 WARNING This procedure must be performed by qualified personnel only Check 1 If the tank 21 contains recovery water Drive the machine to the appointed recovery water disposal area the ignition key 80 to 0 Empty the recovery water tank 21 with the hose 16 Drive the machine on a level floor Remove the brush pad holder Lower the deck by pressing the pedal 11 Turn the ignition key 80 to 0 Carefully lift the tank 40 Apply the amperometric pliers J on one cable K of the brush motor L SCRUBTEC 545BL 553BL BOOST 5 Turn the speed adjuster 84 to idle and turn the ignition key 80 to I Turn on the brush pad holder by pressing the switch 71 and check that the motor electrical input is 3 4 A at 24 V for SCRUBTEC 545B 545BL 553B 553BL and is 10 11 Aat 24 V for SCRUBTEC BOOST 5 Turn off the brush pad holder by pressing the switch 71 Turn the ignition key 80 to 0 Remove the amperometric pliers J If the electrical input is higher perform the following procedures to detect and correct the abnormal input coo oo BON NOTE If the electrical input is higher than the maximum allowed value the 3 battery warning lights 81 flash simultaneously e Check the tightening of F1 fuse screw see the procedure in Fuse Check Replacement paragraph Checkifthere is dust or
40. UBTEC 5458 545BL 5538 553BL BOOST 5 6538 653BL 651BCL 661BL 62 VACUUM SYSTEM MOTOR ELECTRICAL INPUT CHECK SCRUBTEC 545E 553E 653 63 VACUUM SYSTEM MOTOR CARBON BRUSH CHECK REPLACEMENT All models eene 65 VACUUM SYSTEM MOTOR DISASSEMBLY ASSEMBLY All nennen nnne 66 SQUEEGEE SPRING CHECK REPLACEMENT All models with aluminium 67 TROUBLESHOOTING n 68 DRIVE 5 69 MAXIMUM SPEED POTENTIOMETER DISASSEMBLY ASSEMBLY SCRUBTEC 545BL 553BL BOOST 5 653BL 651BCL 6618 69 DRIVE SYSTEM MOTOR ELECTRICAL INPUT CHECK SCRUBTEC 545BL 553BL BOOST 5 653BL 651BCL 661BL 70 DRIVE SYSTEM MOTOR CARBON BRUSH CHECK AND REPLACEMENT SCRUBTEC 545BL 553BL BOOST 5 653BL 651BCL 6 72 DRIVE SYSTEM MOTOR DIFFERENTIAL DISASSEMBLY ASSEMBLY SCRUBTEC 545BL 553BL BOOST 5 653BL 651BCL 66 73 TROUBLESHOOTING EET 74 OTHER d eadc 76 SCREW AND NUT TIGHTENING CHECK All
41. Y ASSEMBLY SCRUBTEC 5458 545BL 5538 553BL 6538 653BL 49 BOOST DECK MOTOR DISASSEMBLY ASSEMBLY SCRUBTEC BOOST 5 sese 50 BOOST DECK VIBRATION DAMPERS DISASSEMBLY REPLACEMENT SCRUBTEC BOOST 5 51 BRUSH MOTOR DISASSEMBLY ASSEMBLY SCRUBTEC 651 52 BRUSH MOTOR DISASSEMBLY ASSEMBLY SCRUBTEC 661 1 53 BRUSH MOTOR DISASSEMBLY ASSEMBLY SCRUBTEC 545E 553E 653 54 CHECK REPLACEMENT ADJUSTMENT OF DRIVING BELTS BETWEEN MOTORS AND CYLINDRICAL BRUSHES SCRUBTEG n 55 TROUBLESHOOTING cMEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEEENEMMMMMMMMMMWMWMWWMWWWWWgWgaaaqaaaqauugggtb2b 57 9097062000 2 2009 06 SCRUBTEC 545B 545BL 553B 553BL BOOST 5 1 6538 653BL 651BCL 661BL 545 553E 653E ENGLISH SERVICE MANUAL RECOVERY WATER SYSTEM cerro kn HERE pini a kt ko e ie n m m n kan n ki n n no m n KE ER n n ER CENE 58 RECOVERY WATER TANK AND VACUUM GRID CLEANING AND COVER GASKET CHECK models 58 SQUEEGEE CLEANING CHECK REPLACEMENT AND SQUEEGEE BLADE REPLACEMENT All models 59 VACUUM SYSTEM MOTOR FILTER CLEANING All 61 VACUUM SYSTEM MOTOR ELECTRICAL INPUT CHECK SCR
42. a pressure function turned on Optional 29 kg Optional 30 kg 34 Kg Battery maximum size Brush and squeegee maximum size Full clean water tank Optional equipment installed Wheel weight checked Each wheel print checked on cement Machine test have been performed under the following conditions Result expressed as maximum value for both front and rear wheels 9097062000 2 2009 06 SCRUBTEC 545B 545BL 553B 553BL BOOST 5 6538 653BL 651BCL 661BL 545E 553E 653E ENGLISH SERVICE MANUAL GENERAL INFORMATION TECHNICAL DATA SCRUBTEC 653B 653BL 651BCL 661BL General technical data SCRUBTEC SCRUBTEC SCRUBTEC SCRUBTEC 653B 653BL 651BCL 661BL Model 1 brush pad 1 brush pad 2 cylindrical 2 brushes pad holder without holder with drive brushes with holders with drive drive system system drive system system Machine height 1 088 mm Solution clean water tank capacity 55 litres Recovery water tank capacity 55 litres Min max solution flow without Chemical Mixing System 0 1 6 It min Min max solution flow with Chemical Mixing System 0 1 5 It min Chemical Mixing System tank capacity 5 litres Chemical Mixing System setting 0 490 2 590 Solution clean water autonomy 1 1 It min 52 min Media Average Front wheel diameter 250 mm 2 Front and rear wheel s
43. al input is 3 4 A at 24 V Turn off the brush pad holder by pressing the switch 71 Turn the ignition key 80 to 0 Remove the amperometric pliers J If the electrical input is higher perform the following procedures to detect and correct the abnormal input NOTE If the electrical input is higher than the maximum allowed value the 3 battery warning lights 81 flash simultaneously e Check the tightening of F1 fuse screw see the procedure in Fuse Check Replacement paragraph e Check if there is dust or dirt ropes cables etc on the brush pad holder hub e Check the motor carbon brushes see the procedure in the relevant paragraph e Disassemble the motor see the procedure in the relevant paragraph and check the condition of all its components If the above mentioned procedures do not lead to a correct electrical input the motor must be replaced see the procedure in the relevant paragraph Reset 10 Perform steps 3 to 7 in the reverse order 5301534 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 40 653B 653BL 651BCL 66181 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ENGLISH BRUSHING SYSTEM BRUSH MOTOR ELECTRICAL INPUT CHECK SCRUBTEC 651BCL WARNING This procedure must be performed by qualified personnel only Check Remove the brushes as shown in the User Manual Lower the deck by pressing the pedal 11 Disconnect the motor which does not have t
44. and clean the brushes 3 The motor is faulty repair or replace 4 The wiring harness is damaged repair SCRUBTEC 545B 545BL 553B 553BL BOOST 5 ak 6538 653BL 651BCL 661BL 545E 553E 653E ai ENGLISH SERVICE MANUAL RECOVERY WATER SYSTEM RECOVERY WATER SYSTEM RECOVERY WATER TANK AND VACUUM GRID CLEANING AND COVER GASKET CHECK All models 1 Drive the machine to the appointed recovery water disposal area 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL Turn the ignition key 80 to 0 SCRUBTEC 545E 553E 653E Disconnect the power supply cable 59 from the electrical mains 3 Lift the cover A to washing position L 4 Wash with clean water the cover A the tank and the vacuum grid with automatic shut off float D Drain the water in the tank through the hose 16 5 f necessary release the fasteners E and open the grid D recover the float clean all the components and then reinstall them 6 Check the tank cover gasket for integrity NOTE i The gasket G creates vacuum in the tank that is necessary for vacuuming the recovery water If necessary replace the gasket by removing it from its housing H When assembling the new gasket install the joint 1 in the rear central area as shown in the figure 7 Check that the seating surface J of the gasket is integral and adequate for the gasket itself NOTE
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46. aragraph 2 Check that the edges Fig 1 or 2 of the front blade and the edges F of the rear blade D lay down on the same level along their length otherwise adjust their height according to the following procedure Release the tie rod G Fig 1 or 2 and loosen the wing nuts H Fig 1 or disengage the fasteners M Fig 2 and adjust the rear blade D Fig 1 or 2 then tighten the wing nuts or engage the fasteners and then engage the tie rod e Loosen the handwheels I and adjust the front blade C Fig 1 or 2 then tighten the handwheels 3 Check the front blade C Fig 1 or 2 and rear blade D for integrity cuts and tears if necessary replace them according to the following procedure Check that the front corner J of the rear blade is not worn otherwise overturn the blade to replace the worn corner with an integral one If the other corners are worn too replace the blade according to the following procedure Release the tie rod remove the wing nuts H or disengage the fasteners M remove the retaining strip then replace overturn the rear blade D Then install the blade in the reverse order of removal Unscrew the handwheels and remove the retaining strip L then replace the front blade C Install the blade in the reverse order of removal After the blade replacement or overturning adjust the height as shown in the previous step 4 Connect the vacuum hose 15 to the squeegee
47. are released Battery charging produces highly explosive hydrogen gas Keep the tanks lifted during battery charging and perform this operation in well ventilated areas and away from naked flames DANGER SCRUBTEC 545E 553E 653E A Always disconnect the power supply cable when the machine is not in use before performing maintenance procedures before replacing the brush pad holder and before opening any access panel gt gt SCRUBTEC 5458 545BL 5538 553BL BOOST 5 4 653B 653BL 651BCL 66181 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ENGLISH GENERAL INFORMATION WARNING avoid any unauthorized use of the machine remove the ignition key Do not leave the machine unattended without being sure that it cannot move independently A Always protect the machine against the sun rain and bad weather both under operation and inactivity condition Store the machine indoors in a dry place This machine must be used in dry conditions it must not be used or kept outdoors in wet conditions Before using the machine close all doors and or covers Do not allow to be used as a toy Close attention is necessary when used near children Use only as shown in this Manual Only Nilfisk recommended accessories must be used Take all necessary precautions to prevent hair jewels and loose clothes from being caught by the machine moving parts not use the machine
48. at A All covers are closed ignition key is removed The machine is securely fastened to the means of transport OTHER REFERENCE MANUALS The following manuals are available at Nilfisk Advance Literature Service Department SCRUBTEC 545B 545BL 553B 553BL BOOST 5 User Manual Form Number 9097054000 SCRUBTEC 545B 545BL 553B 553BL BOOST 5 Spare Parts List Form number 9097055000 SCRUBTEC 653B 653BL 651BCL 661BL User Manual Form Number 9097058000 SCRUBTEC 653B 653BL 651BCL 661BL Spare Parts List Form number 9097059000 SCRUBTEC 545E 553E User Manual Form Number 9097056000 SCRUBTEC 545E 553E Spare Parts List Form number 9097057000 SCRUBTEC 653E User Manual Form Number 9097060000 SCRUBTEC 653E Spare Parts List Form number 9097061000 Assembling Instruction Hour meter Kit Form Number 9096952000 Assembling Instruction Extra Pressure Kit Form Number 909 6759 000 Assembling Instruction Splash Guard Kit Form Number 909 6745 000 Assembling Instruction Battery charger Kit Form Number 909 6746 000 Assembling Instruction Chemical Mixing System Kit Form Number 9097162000 SCRUBTEC 545B 545BL 553B 553BL BOOST 5 2220808 6538 653BL 651BCL 661BL 545 553E 653E a SERVICE MANUAL GENERAL INFORMATION SAFETY The following symbols indicate potentially dangerous situations Always read this information carefully and take all necessary precauti
49. ble 59 from the electrical mains Remove the amperometric pliers E If the electrical input is higher perform the following procedures to detect and correct the abnormal input e Check that the filter 44 is clean see the procedure in the relevant paragraph Check that the vacuum grid with automatic shut off float is clean see the procedure in the relevant paragraph Check that the squeegee and the vacuum hose are clean see the procedure in the relevant paragraph e Check the motor carbon brushes see the procedure in the relevant paragraph If the above mentioned procedures do not lead to a correct electrical input the motor must be replaced see the procedure in the relevant paragraph Reset 11 Perform steps 3 to 7 in the reverse order a SCRUBTEC 545B 545BL 5538 55381 BOOST 5 ki s t ak 06 653B 653BL 651BCL 661BL 545E 553E 653E 94 RECOVERY WATER SYSTEM VACUUM SYSTEM MOTOR ELECTRICAL INPUT CHECK SCRUBTEC 545E 553E 653E Continues 5301554 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 64 653B 653BL 651BCL 661BL 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL RECOVERY WATER SYSTEM VACUUM SYSTEM MOTOR CARBON BRUSH CHECK REPLACEMENT All models Remove the vacuum system motor see the procedure in the relevant paragraph At the workbench remove the cover A press fitted from the vacuum system motor B Remove the screws C Disconn
50. d contact the Nilfisk Service Center or a qualified technician SCRUBTEC 5458 545BL 5538 553BL BOOST 5 653B 653BL 651BCL 661BL 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ENGLISH GENERAL INFORMATION TECHNICAL DATA SCRUBTEC 545B 545BL 553B 553BL BOOST 5 SCRUBTEC SCRUBTEC SCRUBTEC SCRUBTEC SCRUBTEC 545B 545BL 553B 553BL BOOST 5 Model 1 brush pad 1 brush pad 1 brush pad 1 brush pad Vibrator holder holder without holder with holder without holder with with drive drive system drive system drive system drive system system Machine height 1 058 5 mm Solution clean water tank capacity 42 litres Recovery water tank capacity 42 litres Min max solution flow without Chemical Mixing System 0 1 6 It min Min max solution flow with Chemical Mixing System 5 litres 5 litres Chemical Mixing System tank capacity 0 4 2 5 0 4 2 5 Chemical Mixing System setting 0 4 2 5 0 4 2 590 Solution clean water autonomy 1 1 36 min Media Average Front wheel diameter 200 mm Front and rear wheel specific pressure on the floor 0 9 N mm 3 N mm Rear wheel diameter 100 mm Minimum turning radius 600 mm 650 mm Vacuum system motor power 330W Drive system motor power 200W 200W Drive speed variable m 0 to 4 5 km h 0 to 4 5 km h Max gradeabi
51. dirt ropes cables etc on the brush pad holder hub Check the motor carbon brushes see the procedure in the relevant paragraph e Disassemble the motor see the procedure in the relevant paragraph and check the condition of all its components If the above mentioned procedures do not lead to a correct electrical input the motor must be replaced see the procedure in the relevant paragraph Reset 10 Perform steps 3 to 7 in the reverse order 5301533 5 SCRUBTEC 5458 54581 5538 55381 BOOST 5 6538 653BL 651BCL 661BL 545E 553E 653E 39 ENGLISH SERVICE MANUAL BRUSHING SYSTEM BRUSH MOTOR ELECTRICAL INPUT CHECK SCRUBTEC 653B 653BL WARNING This procedure must be performed by qualified personnel only Check 1 o0 0o90 RON If the tank 21 contains recovery water Drive the machine to the appointed recovery water disposal area Turn the ignition key 80 to 0 Empty the recovery water tank 21 with the hose 16 Drive the machine on a level floor Remove the brush pad holder Lower the deck by pressing the pedal 11 Turn the ignition key 80 to 0 Carefully lift the tank 40 Apply the amperometric pliers J on one cable K of the brush motor L SCRUBTEC 653BL Turn the speed adjuster 84 to idle and turn the ignition key 80 to I Turn on the brush pad holder by pressing the switch 71 and check that the motor electric
52. disengaging it from the lower fastener Remove the screws L on the rear side of the electrical panel J then remove the drive system electronic board H Poo ssembly Assemble in the reverse order of disassembly ONDA CAEN 100158 SCRUBTEC 545B 545BL 553B 553BL BOOST 5 6538 653BL 651BCL 661BL 545 553E 653E as ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM DRIVE SYSTEM ELECTRONIC BOARD DISASSEMBLY ASSEMBLY SCRUBTEC 545BL 553BL BOOST 5 653BL 651BCL 661BL Continues 5301574 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 86 653B 653BL 651BCL 66181 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ELECTRICAL SYSTEM FUNCTION ELECTRONIC BOARD DISASSEMBLY ASSEMBLY SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL Disassembly 1 Disconnect the battery connector 12 2 Move aside the recovery water drain hose 16 3 Remove the battery charger cable 6 if equipped from the cable holder 7 4 Remove the screws and carefully move aside the panel B by disengaging the cable grommet from its housing on the panel B 5 Disconnect the connectors D and remove the panel B 6 panel remove the screws then remove the function electronic board H Assembly 7 Assemble in the reverse order of disassembly P100157 5 SCRUB
53. e a level floor SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL Turn the ignition key 80 to 0 SCRUBTEC 545E 553E 653E Disconnect the power supply cable 59 from the electrical mains Check that the springs A and B push the squeegee C on the floor correctly If necessary disassemble and replace the springs according to the following procedure isassembly Remove the squeegee see the procedure in the relevant paragraph Lift the deck by pressing the pedal 11 Grasp the handlebar 2 and lower the front part of the machine Remove the cotter pin D Disengage the end E of the left spring F from the housing G Remove the left spring Repeat steps 8 9 and 10 for the right spring H 5301557 9097062000 2 2009 06 SCRUBTEC 545B 545BL 5538 553BL BOOST 5 67 6538 653BL 651BCL 661BL 545 553E 653E ENGLISH SERVICE MANUAL RECOVERY WATER SYSTEM TROUBLESHOOTING The vacuum system motor does not turn on Possible causes 1 The wiring harness between the function electronic board and the vacuum system relay is damaged or short circuited check and repair The vacuum system relay is damaged replace The wiring harness between relay and motor is damaged repair The vacuum system fuse is open replace The vacuum system motor carbon brushes are worn replace The vacuum system motor is faulty check the elect
54. e FL1 Mains filter FR Machine frame HM Hour counter optional HS Grounding screw M1 Brush pad holder motor M2 Vacuum system motor PL Plug Swi Brush pad holder switch SW2 Vacuum system switch SWS3 Brush pad holder switch on the right of the handlebar SW4 Brush pad holder switch on the left of the handlebar NOTE Figure showing 653E P100150 5 SCRUBTEC 5458 54581 5538 55381 BOOST 5 653B 653BL 651BCL 661BL 545 553E 653E 95 ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM WIRING DIAGRAM SCRUBTEC 545E 553E 653E Key Colour codes C1 Suppression filter BK Black EB1 Water flow electronic board BU Blue ES1 Brush motor relay BN Brown EV1 Water solenoid valve GN Green F1 Electronic board fuse GY Grey FL1 Mains filter OG Orange FR Machine frame PK Pink HM Hour counter optional RD Red HS Grounding screw VT Violet M1 Brush pad holder motor WH White M2 Vacuum system motor YE Yellow PL Plug SW1 Brush pad holder switch SW2 Vacuum system switch SW3 Brush pad holder switch on the right of the handlebar SW4 Brush pad holder switch on the left of the handlebar BN D HM BU 1 2 BN D 5 BN D BU 2 BU 2 SW3 0 4 5 4 BK BN
55. e new grounded outlet installed by a qualified technician according to the law in force Before connecting the power supply cable to the electrical mains check that frequency and voltage shown on the machine serial number plate match the electrical mains voltage Do not unplug the machine by pulling the supply cable To unplug grasp the plug not the cable Do not handle the plug or the machine with wet hands Turn off all controls before unplugging Regularly check the power supply cable for damages cuts cracks and wear If necessary replace it If the power supply cable is damaged contact the Nilfisk Service Center for replacement Do not pull or carry the machine by the power supply cable and never use the power supply cable as a handle Do not close a door on the power supply cable or pull the power supply cable around sharp edges or corners Do not run the machine on the power supply cable The brushes must not come into contact with the power supply cable Keep the power supply cable away from heated surfaces To reduce the risk of fire electric shock or injury do not leave the machine unattended when it is plugged in Disconnect the machine from the electrical mains when not in use and before performing maintenance procedures If the machine does not work properly is damaged has water or foam leaks has been left outdoors exposed to bad weather conditions is wet or has been dropped into water turn it off immediately an
56. e tank There is debris in the solution clean water hoses clogging the flow clean the hoses The solution clean water reaches the brush also when the machine is off Possible causes 1 2 There is dirt or calcium deposit on the solenoid valve gasket clean The solenoid valve is broken replace 32 SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ENGLISH CHEMICAL MIXING SYSTEM CHEMICAL MIXING SYSTEM TROUBLESHOOTING Small amount of detergent or no detergent reaches the brush Possible causes The detergent flow percentage is too low check change the percentage as shown in the User Manual 2 The hydraulic circuit upstream of the detergent pump is not triggered check if the hose 48 is filled and if necessary perform one or more draining cycle as shown in the relevant paragraph The pump is broken or there is an open in the electrical connection replace the pump repair the electrical connection There is debris in the detergent tank clogging the output hole clean the tank There is debris in the detergent hoses clogging the detergent flow clean the hoses The function electronic board is faulty replace The potentiometer is disconnected or faulty The one way valve is clogged replace or clean with compressed air ONDAY The detergent reaches the brush also when the machine is off Possible causes 1 The pump is
57. e the following paragraphs SCHEDULED MAINTENANCE TABLE SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL Daily after using Every six the machine months Procedure Battery charging Squeegee cleaning Brush pad cleaning Tank and vacuum grid with float cleaning and cover gasket check Squeegee blade check and replacement Chemical Mixing System cleaning and draining optional Solution clean water filter cleaning Vacuum system motor filter cleaning WET battery fluid level check Screw and nut tightening check Brush pad holder motor carbon brush check or replacement Vacuum system motor carbon brush check or replacement Drive system motor carbon brush check or replacement SCRUBTEC 545BL 553BL 653BL 651BCL 661BL Vibration dampers replacement only for BOOST 5 1 And after the first 8 working hours SCHEDULED MAINTENANCE TABLE SCRUBTEC 545E 553E 653E Daily after using Every six Procedure the machine months Power supply cable check Squeegee cleaning Brush pad cleaning Tank and vacuum grid with float cleaning and cover gasket check Squeegee blade check and replacement Solution filter cleaning Vacuum system motor filter cleaning Screw and nut tightening check Brush pad holder motor carbon brush check and r
58. e the vacuum system motor filter 44 and clean it with water and compressed air 9 Install the filter 44 Assembly 10 Assemble in the reverse order of disassembly WARNING SCRUBTEC 545E 553E 653E When the maintenance repair procedure is completed the tank 40 must always be locked with the plate 61 a SCRUBTEC 545B 545BL 5538 55381 BOOST 5 ki s t ak 06 653B 653BL 651BCL 661BL 545E 553E 653E x ENGLISH SERVICE MANUAL RECOVERY WATER SYSTEM VACUUM SYSTEM MOTOR ELECTRICAL INPUT CHECK SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL WARNING This procedure must be performed by qualified personnel only 0 If the tank 21 contains recovery water Drive the machine to the appointed recovery water disposal area Turn the ignition key 80 to 0 Empty the recovery water tank 21 with the hose 16 Drive the machine on a level floor Turn the ignition key 80 to 0 Disconnect the battery connector 12 Carefully lift the tank 40 Apply the amperometric pliers on one cable B of the batteries Turn the ignition key 80 to I Turn on the vacuum system by pressing the switch 73 and check that the motor electrical input is 16 19 A at 24 V Turn off the vacuum system motor by pressing the switch 73 Remove the amperometric pliers B If the electrical input exceeds the specifications check the motor carbon brushes see the procedu
59. ect the brush pad holder motor electrical connection D 6 Disconnect the solution hose connection E 7 Remove the screws C then remove the brush pad holder deck A 1 ssembly Assemble the components in the reverse order of disassembly and note the following When the machine is equipped with the cylindrical brush deck 18c the gas spring A must not be installed NOTE Figure showing 653B with one brush D B L 9 i A E E C F 5301531 36 SCRUBTEC 545B 545BL 5538 553BL BOOST 5 6538 65381 651BCL 661BL 545E 553E 653 9097062000 2 2009 06 SERVICE MANUAL BRUSHING SYSTEM BRUSH PAD HOLDER DECK DISASSEMBLY ASSEMBLY SCRUBTEC 545E 553E 653E Disassembly 1 Drive the machine to the appointed disposal area and empty the recovery water tank 21 with the hose 16 2 Remove the brush pad holder as shown in the User Manual 3 Place the machine on a hoisting system if available Otherwise drive the machine on a level floor Disconnect the power supply cable 59 from the electrical mains Open the recovery water tank cover 22 Remove the retaining plate 61 of the tank 40 Carefully lift the tank 40 If the power supply cable 59 is on the holder 60 remove it Move aside the recovery wat
60. ect the electrical connections D Remove the carbon brushes E Check the carbon brushes for wear Replace the carbon brushes when the contact with the motor armature is insufficient the carbon brushes are worn the carbon brush contact surface is not integral the thrust spring is broken etc If necessary replace the carbon brushes Replace the carbon brushes as an assembly 8 Assemble in the reverse order of disassembly 5301555 SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL 545 553 653E ga ENGLISH SERVICE MANUAL RECOVERY WATER SYSTEM VACUUM SYSTEM MOTOR DISASSEMBLY ASSEMBLY All models Disassembly 1 2 2 gt 12 If the tank 21 contains recovery water Drive the machine to the appointed recovery water disposal area SCRUBTEC 5458 545BL 5538 553BL BOOST 5 6538 653BL 651BCL 661BL Turn the ignition key 80 to 0 SCRUBTEC 545E 553E 653E Disconnect the power supply cable 59 from the electrical mains Empty the recovery water tank 21 with the hose 16 Drive the machine on a level floor SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL Turn the ignition key 80 to 0 SCRUBTEC 545E 553E 653E Disconnect the power supply cable 59 from the electrical mains SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL Di
61. eed adjusting handwheel batteries are semi discharged Recovery water tank cover opened 94 Red warning light the battery charger is on and it is Tank cover gasket charging the batteries Cover movable retaining plate Cover fixed retaining plate do not remove Only for SCRUBTEC 545BL 553BL BOOST 5 Serial number plate technical data conformity certification Only for machines with Chemical Mixing System optional Squeegee bumper wheels Only for SCRUBTEC 545B 553B Vacuum grid with automatic shut off float Solution filler neck Filter Deck bumper wheels Recovery water tank opened Detergent clean water hose Tank safety cable Vacuum system motor cover Vacuum system motor sound deadening filter Detergent tank Detergent tank plug Detergent tank handle Detergent feed hose Detergent pump Detergent tank pump connecting hose SCRUBTEC 545B 545BL 553B 553BL BOOST 5 18 653B 653BL 651BCL 661BL 545 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ENGLISH MAINTENANCE MACHINE NOMENCLATURE SCRUBTEC 545B 545BL 553B 553BL BOOST 5 Continues 21 22 1 23 3 2 4 3 5 6 P100101 5 SCRUBTEC 5458 54581 5538 55381 BOOST 5 653B 653BL 651BCL 661BL 545 553 653E 19 ENGLISH SERVICE MANUAL MAINTENANCE MACHINE NOMENCLATURE SCRUBTEC 545B 545BL 553B 553BL BOOST 5 Continues Ti 72 74 73 76 75 79 80 83
62. eplacement Vacuum system motor carbon brush check or replacement 1 And after the first 8 working hours SCRUBTEC 5458 545BL 553B 553BL BOOST 5 a 6538 653BL 651BCL 661BL 545 553 653E u ENGLISH SERVICE MANUAL MAINTENANCE MACHINE NOMENCLATURE SCRUBTEC 545B 545BL 553B 553BL BOOST 5 Throughout this Manual you will find numbers in brackets for example 2 These numbers refer to the components indicated in these two nomenclature pages Refer to these pages whenever it is required to identify a component mentioned in the text 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 3T 38 39 40 41 42 43 44 45 46 4T 48 49 50 Control panel 51 Solution clean water filter Handlebar 52 Solution clean water tap Brush forward gear switch Brush switch 53 Batteries Drive speed adjuster 54 Battery caps Battery charger data inspection window optional 55 Reference table for detergent proportioning Battery charger cable optional 57 Battery connection diagram Battery charger cable holder optional 58 Boost holder Recovery water drain hose plug 59 Pad boost holder Reverse gear switch 71 Brush pad holder switch Squeegee lifting lowering lever 72 Brush pad holder switch warning light Deck lifting lowering pedal 73 Vacuum system switch Pedal pos
63. er drain hose 16 0 Remove the screws A and carefully move the panel B 1 Disconnect the brush motor wiring harness connections C from the electronic board D connections symbols F4 and 5 12 Open the brush motor wiring harness clamps 13 Open the brush motor wiring harness clamps F 14 Lower the deck by pressing the pedal 11 15 Disconnect the solution hose connection G 16 Remove the screws H and P then remove the brush pad holder deck I with the relevant motor and wiring harness gt Assembly 1 Assemble the components in the reverse order of disassembly and note the following e When installing the deck 1 on the machine use the handwheel to centre the screw hole P WARNING AN When the maintenance repair procedure is completed the tank 40 must always be locked with the plate 61 NOTE Figure showing SCRUBTEC 545E SCRUBTEC 5458 545BL 553B 553BL BOOST 5 ak 653B 653BL 651BCL 661BL 545 553 653E M ENGLISH SERVICE MANUAL BRUSHING SYSTEM BRUSH PAD HOLDER DECK DISASSEMBLY ASSEMBLY SCRUBTEC 545E 553E 653E Continues P100151 SCRUBTEC 545B 545BL 5538 553BL BOOST 5 38 653B 653BL 651BCL 661BL 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL BRUSHING SYS
64. eries or clean the connections 2 batteries are broken check the battery no load voltage NOTE In the machines equipped with on board battery charger a fault in the battery charger and relevant connections can affect the machine operation 3 The battery charger is broken replace only for machine equipped with on board battery charger 4 There is an open in the fuses replace 5 The wiring harness is cut pressed or short circuited repair 6 Error codes indicated by LEDs 81a 81b 81c Flashes Meaning Action Perform checks shown in BRUSH MOTOR ELECTRICAL INPUT CHECK Green yellow ang reg LED Problem related to brush motor overload flashing simultaneously If check results are negative check the F1 fuse for integrity and tightness Charge the batteries Red LED flashing The batteries are discharged If the problem persists replace them 9097062000 2 2009 06 SCRUBTEC 545B 545BL 553B 553BL BOOST 5 89 653B 653BL 651BCL 661BL 545E 553E 653E ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM COMPONENT LAYOUT SCRUBTEC 545B 553B 653B Key BAT 24 V battery C1 Battery connector C2 Battery charger connector CH Battery charger optional CS Deck connector EB1 Function electronic board ES1 Brush electromagnetic switches ES2 Vacuum system relay EV1 Water solenoid valve F1 Deck fuse
65. f equipped 7 Remove the battery charger data inspection window screws A 8 Remove the window B 9 Turn the battery charger selector C to WET position for lead batteries or to GEL position for gel batteries 10 Install the window B and tighten the screws A P100105 SCRUBTEC 545B 545BL 553B 553BL BOOST 5 2220808 6538 653BL 651BCL 661BL 545 553E 653E d SERVICE MANUAL ELECTRICAL SYSTEM BATTERY TYPE SETTING WET OR GEL SCRUBTEC 545BL 553BL BOOST 5 653BL 651BCL 661BL Set the electronic board of the machine and of the battery charger if equipped according to the type of batteries installed WET or GEL according to the following procedure Machine setting 1 the ignition key 80 to I and pay attention to the following in the very first seconds of machine operation Ifthe green warning light 81a is flashing the machine is set to GEL the red warning light 81c is flashing the machine is set to WET If the setting is to be changed perform the following procedure Turn off the machine by turning the ignition key 80 to O Press and hold the switches 71 and 73 at the same time then turn the ignition key 80 to I Release the switches 71 and 73 at least 8 seconds after starting the machine Within three seconds press the switch 73 again for a few seconds and check that the warning light for the required setting is flashing as show
66. i ELECTRICAL SYSTEM FUSE CHECK REPLACEMENT SCRUBTEC 545E 553E 653E Disconnect the power supply cable 59 from the electrical mains but do not place it on the holder 60 If the power supply cable 59 is on the holder 60 remove it Move aside the recovery water drain hose 16 Remove the screws A and carefully move the panel B Check replace the following fuse C Electronic board fuse FL 1 Perform steps 2 to 4 in the reverse order Oo ROMA D a P100114 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 82 6538 653BL 651BCL 661BL 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ELECTRICAL SYSTEM BRUSH MOTOR ELECTROMAGNETIC SWITCH DISASSEMBLY ASSEMBLY SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL Disassembly 1 Disconnect the battery connector 12 2 Move aside the recovery water drain hose 16 3 Remove the battery charger cable 6 if equipped from the cable holder 7 4 Remove the screws and carefully move aside the panel B by disengaging the cable grommet from its housing on the panel B 5 Disconnect the connectors D E and remove the panel B 6 Disconnect the terminals and from the electromagnetic switch J Disconnect also the terminals 1 which are only on models equipped with drive system 7 Remove the screws and move the elect
67. in the reverse order of disassembly and note the following The electrical connections H of the motor must be turned upwards connection J of the carbon brush protection clamps 1 must be positioned as shown the figure e Install the belt E and tension it properly see the procedure in the relevant paragraph 5301545 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 52 653B 653BL 651BCL 66181 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL BRUSHING SYSTEM BRUSH MOTOR DISASSEMBLY ASSEMBLY SCRUBTEC 661BL Disassembly 1 Remove the brush pad holder deck see the procedure in the relevant paragraph 2 At the workbench remove the screw A from the reduction unit which has to be disassembled 3 Remove the hub assembly B with a puller 4 Remove the screws C 5 Remove the reduction unit D 6 Recover the key E A T ssembly Assemble in the reverse order of disassembly 5301546 SCRUBTEC 5458 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL 545E 553E 653E 58 ENGLISH SERVICE MANUAL BRUSHING SYSTEM BRUSH MOTOR DISASSEMBLY ASSEMBLY SCRUBTEC 545E 553E 653E Disassembly 1 2 3 4 5 6 7 8 A 9 Remove the brush pad holder deck see the procedure in the relevant paragraph At the workbench remove the screw A Remove the hub assembly B with a puller Remove the screws C
68. ing the pedal 11 4 Remove the cotter pins B then remove the gas spring A 5 Disconnect the brush pad holder motor electrical connection D 6 Remove the screw E and disconnect the solenoid valve connection F 7 Disconnect the solution hose connection 8 Remove the screws C then remove the brush pad holder deck H A 1 ssembly Assemble in the reverse order of disassembly 5301530 SCRUBTEC 5458 545BL 553B 553BL BOOST 5 90192088 ak 6538 653BL 651BCL 661BL 545E 553E 653E as SERVICE MANUAL BRUSHING SYSTEM BRUSH PAD HOLDER DECK OR CYLINDRICAL BRUSH DECK DISASSEMBLY ASSEMBLY SCRUBTEC 653B 653BL 651BCL 661BL The machine can be equipped with either the brush pad holder deck 18a and 18b or the cylindrical brush deck 18c according to the following procedures WARNING When the deck is installed removed it may be necessary to change the squeegee too because they must have the same width For correct matching of deck and squeegee see the Squeegee Installation paragraph in the User Manual Disassembly 1 Drive the machine on a level floor 2 Remove the brushes pad holders as shown in the User Manual Do not remove the cylindrical brushes 3 Lower the brush pad holder deck by pressing the pedal 11 4 Remove the cotter pins B then remove the gas spring A if equipped 5 Disconn
69. ition when deck is lifted 74 Vacuum system switch warning light Pedal position when deck is lowered 75 Brush pad holder release switch Extra pressure activation optional 76 Brush pad holder release switch warning light Battery connector red this connector also works as 77 Detergent flow control knob EMERGENCY push button to stop immediately all 78 Reverse gear switch functions 79 Hour counter optional Rear steering wheels 80 Ignition key 0 1 Front wheels on fixed axle Driving wheels 81 Battery charge indicator Squeegee vacuum hose 81a Charged battery warning light green Recovery water drain hose 81b Semi discharged battery warning light yellow Solution clean water drain and level check hose 81c Discharged battery warning light red Brush pad holder deck 82 Washing water flow control switches Brush pad holder 82a Flow increase switch Solution clean water tank 82b Flow decrease switch Recovery water tank 82c Washing water flow indicator Recovery water tank cover 83 Brush forward gear switch Brush switch Can holder 84 Speed adjuster Solenoid valve 90 Electronic battery charger Squeegee 91 Lead WET or gel GEL battery selector Squeegee mounting handwheels 92 Green warning light the battery charger is on and batteries Squeegee adjusting handwheel are charged Machine straight forward movement adjusting handwheel 93 Yellow warning light the battery charger is on and Machine forward sp
70. l protection Check the drive system motor electrical input 6 Faulty drive system electronic board Replace the drive system electronic board Check the drive system motor electrical input if the electrical 7 Overcurrent output A a input is normal replace the drive system electronic board Check the drive system fuse and the drive system electronic 8 Missing power connection board wiring harness if the fuse and the wiring harness are normal replace the drive system electronic board 9 Low battery voltage Charge the batteries 10 High battery voltage Check the batteries 11 Overload output Check the drive system motor electrical input 12 Not applicable Check for false contacts in the ignition key function 13 Ignition key wrong sequence electronic board drive system electronic board circuit orange cables 14 Software error Replace the drive system electronic board B Flashing of led A of the drive system electronic board 9097062000 2 2009 06 5301565 SCRUBTEC 5458 545BL 553B 553BL BOOST 5 75 6538 653BL 651BCL 661BL 545E 553E 653E ENGLISH SERVICE MANUAL OTHER SYSTEMS OTHER SYSTEMS SCREW AND NUT TIGHTENING CHECK All models 1 Drive the machine to the appointed disposal area and empty the recovery water tank 21 with the hose 16 2 the machine on hoisting system if available Otherwise drive the machine on a level floor 3 SCRUBTEC 5458 545
71. lity 16 9 16 9 Working gradeability 2 Sound pressure level at the operator s position ISO 11201 ISO 4871 LpA 66 dB A 3dB A Sound pressure level to the machine ISO 3744 ISO 4871 LwA 84 dB A Vibration level at the operator s arms ISO 5349 1 2 5 m s Standard batteries 2 x 12 V 95 165 Ah 20h Standard batteries autonomy 3 21 2 6h 3 21 2 6h 2 4h Battery compartment size width x length x height 350 x 350 x 300 mm Total consumption in work condition 29A Vacuum system circuit capacity 1 055 mm H O Cleaning width 450 mm 530 mm 510 mm Squeegee width 760 mm Machine maximum length 1 190 mm 1 228 mm Machine width without squeegee 512 mm 540 8 mm Brush diameter 450 mm 530 mm 355 x 508 mm Deck right left offset 37 1 mm 75 9 mm 83 mm Brush distance from the ground when lifted 60 1 mm 57mm Weight without batteries and with empty tanks 81 kg 96 kg 81 kg 96 kg 92 kg Maximum weight with batteries and full tanks 213 kg 229 kg 213 kg 229 kg 182 kg Brush motor power 480 W 560 W Brush speed 153 rpm 2250 giri min Brush pad holder pressure with extra pressure function turned off 19 0 kg 20 5 kg 18 Kg Brush pad holder pressure with extr
72. ll or carry the machine by the battery charger cable and never use the battery charger cable as a handle Do not close a door on the battery charger cable or pull the battery charger cable around sharp edges or corners Do not run the machine on the battery charger cable Keep the battery charger cable away from heated surfaces Do not charge the batteries if the battery charger cable or the plug are damaged If the machine is not working as it should has been damaged left outdoors or dropped into water return it to the Service Centre Before using the battery charger ensure that frequency and voltage values indicated on the machine serial number plate match the electrical mains voltage Do not smoke while charging the batteries To reduce the risk of fire electric shock or injury do not leave the machine unattended when it is plugged in Before performing any maintenance procedure disconnect the battery charger cable from the electrical mains WARNING SCRUBTEC 545E 553E 653E The machine power supply cable is grounded and the relevant plug is grounded too In case of machine malfunction or breakdown grounding connection reduces the risk of electric shock The power supply cable plug must be connected to an appropriate outlet which is grounded according to law in force Improper connection can cause electric shock Do not tamper with the power supply cable plug If the power supply cable plug cannot be connected to the outlet hav
73. mm 810 mm A DIMENSIONS SCRUBTEC 545E E LJ 5 L 9 AT 1 190 mm 760 mm Als 0 m io SCRUBTEC 545B 545BL 553B 553BL BOOST 5 15 9097062000 2 2009 06 6538 653BL 651BCL 661BL 545 553E 653E MAINTENANCE DIMENSIONS SCRUBTEC 553E 1 058 5 mm 1 190 mm Co Eti 540 8 mm e DIMENSIONS SCRUBTEC 653E E E e 1 323 mm 760 mm E Yi 5 L gt x SCRUBTEC 545B 545BL 553B 553BL BOOST 5 9097062000 2 2009 06 16 653B 653BL 651BCL 661BL 545E 553E 653E SERVICE MANUAL ENGLISH MAINTENANCE MAINTENANCE The lifespan of the machine and its maximum operating safety are ensured by correct and regular maintenance WARNING AN Read carefully the instructions in the Safety chapter before performing any maintenance procedure The following tables provide the scheduled maintenance The intervals shown may vary according to particular working conditions which are to be defined by the person in charge of the maintenance For instructions on maintenance procedures se
74. n in step 1 DARN Battery charger setting if equipped 7 Remove the battery charger data inspection window screws A 8 Remove the window B 9 the battery charger selector to WET position for lead batteries to GEL position for gel batteries 10 Install the window B and tighten the screws A P100105 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 80 653B 653BL 651BCL 66181 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ELECTRICAL SYSTEM FUSE CHECK REPLACEMENT SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL 1 Disconnect the battery connector 12 2 Move aside the recovery water drain hose 16 3 Remove the battery charger cable if equipped from the cable holder J 4 Remove the screws A and carefully move aside the panel B by disengaging the grommet from its housing on the panel B 5 Check replace the following fuses C Deck fuse F1 40 A D Vacuum system fuse F2 30 A Drive system fuse F3 30 A Signal circuits fuse F4 3 A Brush pad holder release fuse F5 20 A Pump fuse F6 3 A Only SCRUBTEC 545BL 553BL BOOST 5 653BL 651 661BL 6 Perform steps 1 to 4 in the reverse order A MCA RIT EN A P100110 SCRUBTEC 5458 545BL 553B 553BL BOOST 5 ak 6538 653BL 651BCL 661BL 545E 553E 653E a
75. nd the driving wheels remove the debris 2 motor is damaged check the motor electrical input 3 The floor gradient is excessive do not use the drive system on slopes with a gradient exceeding the specifications 4 There is a short circuit in the drive system electronic board wiring harness repair 5 The drive system electronic board is faulty replace The machine does not move Possible causes The battery voltage is too low charge the batteries The drive paddle potentiometer 83 is misadjusted or broken adjust or replace The speed adjuster 84 is broken replace The drive system enabling microswitch is misadjusted or broken adjust or replace The drive system electronic board is faulty replace There is an open in the fuse repair The wiring harness is damaged repair The drive system motor carbon brushes are worn replace The drive system motor is faulty replace CONOARWN gt SCRUBTEC 5458 545BL 5538 553BL BOOST 5 74 653B 653BL 651BCL 66181 545 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ENGLISH TROUBLESHOOTING Continues Drive system electronic board diagnostic table DRIVE SYSTEM No of flashes Meaning Action 1 Drive system brush enabling microswitch closed when starting the machine Check the SW1 switches 2 Reverse gear switch closed when starting the machine Check the switch SW2 5 Therma
76. nical data for machines with brush pad holder deck SCRUBTEC 653B SCRUBTEC 653BL SCRUBTEC 661BL Model 1 brush pad holder 1 brush pad holder with 2 brushes pad holders without drive system drive system with drive system Cleaning width 530 mm 530 mm 610 mm Squeegee width 760 mm 810 mm Machine maximum length 1 323 mm 1 311 mm Machine width without squeegee 541 mm 646 mm Brush diameter 530 mm 305 mm Deck right left offset 77 mm 87 80 mm Brush distance from the ground when lifted 59 5 mm 69 5 mm Weight without batteries and with empty tanks 87 kg 95 kg Maximum weight with batteries and full tanks 234 kg 241 kg Brush motor power 480W 350W Brush speed 153 rpm 230 rpm Brush pad holder pressure with extra pressure function turned off 20 kg Brush pad holder pressure with extra pressure function turned on Optional 40 kg Technical data for machines with cylindrical brush deck Model SCRUBTEC 651 BCL 2 cylindrical brushes with drive system Cleaning width 510 mm Squeegee width 760 mm Machine maximum length 1 253 mm Machine width without squeegee 575 5 mm Cylindrical brush size diameter x length 110 x 485 mm Deck right left offset 94 4 5 mm Brush distance from the ground when lifted 39 5 mm Weight without batteries and with empty tanks 105 kg Maximum weight with batteries and full tanks 251 kg Brush motor power 400 Cylindrical brush speed 570 rpm Cylindrical brush pressure 26 5 kg 9097062000 2 2009 06 SCRUBTEC 545B 545BL 553B
77. o be checked Apply the amperometric pliers on one cable B of the brush motor Turn the speed adjuster 84 to idle and turn the ignition key 80 to I Turn on the brushes by pressing the switch 71 and check that the motor electrical input is 5 8 A at 24 V Turn off the brushes by pressing the switch 71 Turn the ignition key 80 to 0 Remove the amperometric pliers A If the electrical input is higher perform the following procedures to detect and correct the abnormal input PAROS NOTE i If the electrical input is higher than the maximum allowed value the 3 battery warning lights 81 flash simultaneously e Check the tightening of F1 fuse screw see the procedure in Fuse Check Replacement paragraph e Check if there is dust or dirt ropes cables etc on the brush hub Check the motor carbon brushes see the procedure in the relevant paragraph Disassemble the motor see the procedure in the relevant paragraph and check the condition of all its components If the above mentioned procedures do not lead to a correct electrical input the motor must be replaced see the procedure in the relevant paragraph Reset 7 Perform steps 1 and 2 in the reverse order 5301535 SCRUBTEC 545B 545BL 553B 553BL BOOST 5 6538 65381 651BCL 661BL 545 553E 653E i ENGLISH SERVICE MANUAL BRUSHING SYSTEM BRUSH MOTOR ELECTRICAL INPUT CHEC
78. om sg Tel 65 6 759 9100 Fax 65 6 759 9133 SPAIN Nilfisk ALTO Division of Nilfisk Advance S A Torre DAra Paseo del Rengle 5 PI 10 E 08302 Matar Tel 34 902 200 201 Fax 34 93 757 8020 E mail mkt nilfisk advance es www nilfisk alto com SWEDEN ALTO Sverige AB Member of Nilfisk Advance Group Aminogatan 18 Box 4029 S 431 04 M lndal Sweden Tel 46 31 706 73 00 Fax 46 31 706 73 40 E mail info nilfisk alto se www nilfisk alto se TAIWAN Nilfisk Advance Taiwan Branch No 5 Wan Fang Road Taipei Taiwan R O C Tel 886 227 002 268 Fax 886 227 840 843 THAILAND Nilfisk Advance Co Ltd 89 Soi Chokechai Ruammitr Viphavadee Rangsit Road Ladyao Jatuchak Bangkok 10900 Thailand Tel 466 2 275 5630 Fax 66 2 691 4079 TURKEY Nilfisk Advance Profesional Temizlik Ekipmanlari Tic A S Cad 48 Yenisahra Kadik y Istanbul Turkey Tel 90 216 470 08 60 90 216 470 08 63 www nilfisk advance com UNITED KINGDOM Nilfisk ALTO Division of Nilfisk Advance Ltd Bowerbank Way Gilwilly Industrial Estate Penrith Cumbria CA11 9BQ Great Britain Tel 44 0 1768 868995 Fax 44 0 1768 864713 E mail sales nilfisk alto co uk www nilfisk alto co uk VIETNAM Nilfisk Advance Representative Office No 46 Doc Ngu Str Ba Dinh Dist Hanoi SR Vietnam Tel 84 4 761 5642 Fax 84 4 761 5643 E mail nilfisk vnn
79. on optional 7T Detergent flow control knob 12 Battery connector red This connector also works as 78 Reverse gear switch EMERGENCY push button to stop immediately all 79 Hour counter optional functions 80 Ignition key 0 l 13 Rear steering wheel 81 Battery charge indicator 14 Front wheels on fixed axle Driving wheels 81a Charged battery warning light green 15 Squeegee vacuum hose 81b Semi discharged battery warning light yellow 16 Recovery water drain hose 81c Discharged battery warning light red 17 Solution clean water drain and level check hose 82 Washing water flow control switches 18a Deck with one brush pad holder 82a Flow increase switch 18b Deck with two brushes pad holders 82b Flow decrease switch 18c Deck with two cylindrical brushes 82c Washing water flow indicator 19a Brushes pad holders 83 Brush forward gear switch Brush switch 19b Cylindrical brushes 84 Speed adjuster 20 Solution clean water tank 90 Electronic battery charger 21 Recovery water tank 91 Lead WET or gel GEL battery selector 22 Recovery water tank cover 92 Green warning light ON the battery charger is on and 23 Can holder batteries are charged 24 Solenoid valve 93 Yellow warning light ON the battery charger is on and 25 Squeegee batteries are semi discharged 26 Squeegee mounting handwheels 94 Red warning light ON the battery charger is on and it is 27 Squeegee adjusting handwheel cha
80. on during machine transportation when temperature is below freezing point The water in the recovery tank or in the hoses could freeze and seriously damage the machine Use brushes and pads supplied with the machine and those specified in the User Manual Using other brushes or pads could reduce safety case of machine malfunctions ensure that these are not due to lack of maintenance Otherwise request assistance from the authorised personnel or from an authorised Service Center f parts must be replaced require ORIGINAL spare parts from a Dealer or Authorised Retailer ensure machine proper and safe operation the scheduled maintenance shown in the relevant chapter of this Manual must be performed by the authorised personnel or by an authorised Service Center Carefully read all the instructions before performing any maintenance repair procedure Do not wash the machine with direct or pressurised water jets or with corrosive substances The machine must be disposed of properly because of the presence of toxic harmful materials batteries etc which are subject to standards that require disposal in special centres see the User Manual 5 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 909706290812 2009 06 6538 653BL 651BCL 661BL 545 553E 653E ENGLISH SERVICE MANUAL GENERAL INFORMATION A WARNING SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL Do not pu
81. ons to safeguard people and property SYMBOLS DANGER It indicates a dangerous situation with risk of death for the operator WARNING It indicates a potential risk of injury for people or damage to objects CAUTION It indicates a caution related to important or useful functions Pay careful attention to the paragraphs marked by this symbol NOTE It indicates a remark related to important or useful functions CONSULTATION It indicates that it is necessary to consult the User Manual before performing any procedure HOPE GENERAL INSTRUCTIONS Specific warnings and cautions to inform about potential damages to people and machine are shown below DANGER This machine must be used by properly trained operators only Children or disabled people cannot use this machine Do not wear jewels when working near electrical components not work under the lifted machine without supporting it with safety stands Do not operate the machine near toxic dangerous flammable and or explosive powders liquids or vapours This machine is not suitable for collecting dangerous powders DANGER SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL Before performing any cleaning maintenance repair or replacement procedure disconnect the battery connector and remove the ignition key Keep the battery far from sparks flames and incandescent material During the normal operation explosive gases
82. optional SW1 Brush drive system enabling switch RD RD Without charger RD RD RD versions Versioni senza caricabatterie r 9tCe3 c24 gt 03 BN 24 Ca WH RD W M a 2 RV3 j 21 52 53 JM 13 00 A 18 aus BU UG Eu w an ESI BAT lan ao sik Dl WH Ch ES FS With clindricol decks tea i ks E versine Versioni con testata F6 a spazz cilindriche J21 3U 436 AN cese J22 5 Es as WH Q 0 i 3 FI 9 06 y ESe 87 18 BK BK BK BK BK lt 9097062000 2 2009 06 SCRUBTEC 5458 545BL 553B 553BL BOOST 5 6538 653BL 651BCL 661BL 545E 553E 653E P100127 91 ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM COMPONENT LAYOUT SCRUBTEC 545BL 553BL BOOST 5 653BL 651BCL 661BL Key BAT 24 V battery C1 Battery connector C2 Battery charger connector CH Battery charger optional CSC Cylindrical brush deck sub connector EB1 Function electronic board EB2 Drive system electronic board ES1 Brush electromagnetic switches ES2 Vacuum system relay EV1 Water solenoid valve F1 Deck fuse F2 Vacuum system fuse F3 Drive system fuse F4 Signal circuit fuse F5 Brush pad holder release fuse F6 Pump fuse HM Hour counter optional K1 Ignition key M1 Brush pad holder m
83. or 2 SCRUBTEC 653BL 651BCL 661BL Turn the ignition key 80 to 0 SCRUBTEC 653E Disconnect the power supply cable 59 from the electrical mains 3 Close the solution tap A Fig 8 under the machine left lower side The tap A is closed when it is in the position B and it is open when it is in the position C 4 Remove the transparent cover D then remove the filter strainer E Clean and install them on the support F NOTE e The filter strainer E must be correctly positioned on the housing G of the support F 5 Open the tap SS P100118 SCRUBTEC 5458 545BL 553B 553BL BOOST 5 ak 653B 653BL 651BCL 661BL 545 553 653E 29 SERVICE MANUAL SOLUTION CLEAN WATER SUPPLY SYSTEM SOLENOID VALVE DISASSEMBLY ASSEMBLY SCRUBTEC 545B 545BL 553B 553BL BOOST 5 545 553E Disassembly 1 Remove the brush 2 Lowerthe deck by pressing the pedal 11 3 Remove the screw A disconnect the connector and recover the gasket 4 Disconnect the union C from the solenoid valve D and recover the gasket 5 Remove the screws E 6 Slightly lift the solenoid valve D disconnect the union F and recover the gasket 7 A 8 Recover the solenoid valve D ssembly Assemble in the reverse order of disassembly 5301522 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 30 653B 653BL 651BCL 66181 545 553E
84. order 5301536 BRUSH MOTOR ELECTRICAL INPUT CHECK SCRUBTEC 545E 553E 653E SCRUBTEC 5458 545BL 5538 553BL BOOST 5 42 653B 653BL 651BCL 66181 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ENGLISH BRUSHING SYSTEM WARNING This procedure must be performed by qualified personnel only Check Remove the brush as shown in the User Manual Disconnect the power supply cable 59 from the electrical mains but do not place it on the holder 60 If the power supply cable 59 is on the holder 60 remove it Move aside the recovery water drain hose 16 Remove the mounting screws A of the panel C Loosen the mounting screws B of the panel C Carefully move backwards the upper end D of the panel C Apply the amperometric pliers E on one cable F connection symbols F4 or F5 of the brush motor Connect the power supply cable 59 to the electrical mains Turn on the brush by pressing the switch 62 and check that the motor electrical input is 3 4 A at 230 V Turn off the brush by pressing the switch 62 Disconnect the power supply cable 59 from the electrical mains Remove the amperometric pliers E If the electrical input is higher perform the following procedures to detect and correct the abnormal input e Check if there is dust or dirt ropes cables etc on the brush hub Check the motor carbon brushes see the procedure in the
85. otor M2 Vacuum system motor M3 Drive system motor M5 Detergent pump optional RV2 Maximum speed potentiometer RV3 Detergent potentiometer optional SW1 Brush drive system enabling switch SW2 gear switch RV3 SW2 HM P100148 SCRUBTEC 545B 545BL 553B 553BL BOOST 5 92 6538 653BL 651BCL 661BL 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM COMPONENT LAYOUT SCRUBTEC 545BL 553BL BOOST 5 653BL 651BCL 661BL Continues LEN l 4 P100149 SCRUBTEC 5458 545BL 553B 553BL BOOST 5 kaki 653B 653BL 651BCL 661BL 545E 553E 653E 83 ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM WIRING DIAGRAM SCRUBTEC 545BL 553BL BOOST 5 653BL 651BCL 661BL Key Colour codes BAT 24 V battery BK Black C1 Battery connector BU Blue C2 Battery charger connector BN Brown CH Battery charger optional GN Green CSC Cylindrical brush deck sub connector GY Grey EB1 Function electronic board OG Orange EB2 Drive system electronic board PK Pink ES1 Brush electromagnetic s
86. pecific pressure on the floor 1 0 8 N mm 6 1 N mm Rear wheel diameter 100 mm Minimum turning radius 700 mm Vacuum system motor power 330W Drive system motor power 200W Drive speed variable 0 to 5 6 km h Max gradeability 1690 9 Working gradeability 296 1 Sound pressure level at the operator s position ISO 11201 ISO 4871 LpA 65 8 dB A 3dB A Sound pressure level to the machine ISO 3744 ISO 4871 LwA Vibration level at the operator s arms ISO 5349 1 2 5 m s Standard batteries 2 x 12 V 95 165 Ah 20h Standard batteries autonomy 3 2h 2 6h Battery compartment size width x length x height 350 x 350 x 300 mm Total consumption in work condition 29A Vacuum system circuit capacity 1 055 mm H O Machine test have been performed under the following conditions Battery maximum size Brush and squeegee maximum size Full clean water tank Optional equipment installed Wheel weight checked Each wheel print checked on cement Result expressed as maximum value for both front and rear wheels 8 SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL GENERAL INFORMATION TECHNICAL DATA SCRUBTEC 653B 653BL 651BCL 66181 continues Tech
87. re in the relevant paragraph If necessary disassemble the vacuum system motor see the procedure in the relevant paragraph and check the condition of its moving parts If the above mentioned procedures do not lead to a correct electrical input the motor must be replaced see the procedure in the relevant paragraph Perform steps 4 and 5 in the reverse order 5301553 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 62 653B 653BL 651BCL 661BL 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL RECOVERY WATER SYSTEM VACUUM SYSTEM MOTOR ELECTRICAL INPUT CHECK SCRUBTEC 545E 553E 653E WARNING This procedure must be performed by qualified personnel only Check Remove the brush as shown in the User Manual Disconnect the power supply cable 59 from the electrical mains but do not place it on the holder 60 If the power supply cable 59 is on the holder 60 remove it Move aside the recovery water drain hose 16 Remove the mounting screws A of the panel C Loosen the mounting screws B of the panel C Carefully move backwards the upper end D of the panel C Apply the amperometric pliers E on one cable F of the vacuum system motor Connect the power supply cable 59 to the electrical mains 0 on the vacuum system by pressing the switch 63 and check that the motor electrical input is 2 2 5 A at 230 V Turn off the vacuum system by pressing the switch 63 Disconnect the power supply ca
88. rging the batteries 28 Machine straight forward movement adjusting handwheel 29 Machine forward speed adjusting handwheel Only for SCRUBTEC 653BL 651BCL 661BL 30 Recovery water tank cover Only for machines with Chemical Mixing System optional 31 Tank cover gasket 7 Only for SCRUBTEC 6538 32 Cover movable retaining plate 33 Cover fixed retaining plate do not remove 34 Serial number plate technical data conformity certification 35 Squeegee bumper wheels 36 Vacuum grid with automatic shut off float 37 Solution clean water front filler neck 38 Filter 39 Deck bumper wheels 40 Recovery water tank opened 41 Solution clean water rear filler neck 42 Tank safety cable 43 Vacuum system motor cover 44 Vacuum system motor sound deadening filter 45 Detergent tank 46 Detergent tank plug 47 Detergent tank handle 48 Detergent feed hose 49 Detergent pump 50 Detergent tank pump connecting hose 9097062000 2 2009 06 SCRUBTEC 545B 545BL 5538 553BL BOOST 5 21 6538 653BL 651BCL 661BL 545 553E 653E ENGLISH SERVICE MANUAL MAINTENANCE MACHINE NOMENCLATURE SCRUBTEC 653B 653BL 651BCL 661BL Continues 21 22 23 1 2 4 2 i n av 39 A ER e IL S i P100115 SCRUBTEC 545B 545BL 553B 553BL BOOST 5 90970
89. rical input The function electronic board is damaged replace Dirty water vacuuming is insufficient or there is no vacuuming Possible causes 1 NOaR WN The vacuum grid with automatic shut off float is activated because the recovery water tank is full empty the recovery water tank The vacuum grid with automatic shut off float is dirty or the vacuum pre filter is dirty clean The tank cover is not correctly positioned adjust The tank cover gasket is not efficient or the compensating hole is clogged repair clean The vacuum system motor filter is dirty clean The squeegee or the vacuum hose is clogged or damaged clean or repair replace The vacuum gaskets are damaged or do not match perfectly repair or replace The squeegee leaves lining on the floor or does not collect water Possible causes Bom There is debris under the blade remove The squeegee blade edges are torn or worn replace The squeegee is not balanced adjust it with the relevant handwheel For aluminium squeegee The squeegee springs are not efficient check replace 68 SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 65381 651BCL 661BL 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ENGLISH DRIVE SYSTEM DRIVE SYSTEM MAXIMUM SPEED POTENTIOMETER DISASSEMBLY ASSEMBLY SCRUBTEC 545BL 553BL BOOST 5 653BL 651BCL 661BL Disassembly 1 Disconnect the battery connector 12 2 Operating inside the
90. rical panel L by disengaging it from the lower fastener M 8 Remove the screws on the rear side of the electrical panel L then remove the electromagnetic switch J Assembly 9 Assemble in the reverse order of disassembly Mt 3 ga N S N y KA P100159 5 SCRUBTEC 5458 54581 5538 55381 BOOST 5 6538 653BL 651BCL 661BL 545E 553E 653E Bd ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM BRUSH MOTOR ELECTROMAGNETIC SWITCH DISASSEMBLY ASSEMBLY SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL Continues S301572 SCRUBTEC 5458 545BL 5538 55381 BOOST 5 84 653B 653BL 651BCL 66181 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ELECTRICAL SYSTEM DRIVE SYSTEM ELECTRONIC BOARD DISASSEMBLY ASSEMBLY SCRUBTEC 545BL 553BL BOOST 5 653BL 651BCL 661BL Disassembly Disconnect the battery connector 12 Move aside the recovery water drain hose 16 Remove the battery charger cable 6 if equipped from the cable holder 7 Remove the screws and carefully move aside the panel B by disengaging the cable grommet from its housing on the panel B Disconnect the connectors D E F and remove the panel B Disconnect the connectors G of the drive system electronic board H Remove the screws 1 and move the electrical panel J by
91. rushes are worn the carbon brush contact surface is not integral the thrust spring is broken etc Replace the carbon brushes as an assembly Reset 7 Assemble in the reverse order of disassembly 5301542 5 SCRUBTEC 5458 54581 5538 55381 BOOST 5 a 653B 653BL 651BCL 661BL 545E 553E 653E i ENGLISH SERVICE MANUAL BRUSHING SYSTEM BRUSH MOTOR CARBON BRUSH CHECK REPLACEMENT SCRUBTEC 661BL Check Remove the cylindrical brush deck see the procedure in the relevant paragraph At the workbench remove dust and debris from the motor especially in the area of the carbon brushes Remove four protection covers A by disengaging the fasteners Remove the carbon brush nuts B with the lead in wires Disengage the tabs C and remove the carbon brushes D Check the carbon brushes D for wear Replace the carbon brushes when the contact with the motor armature is insufficient the carbon brushes are worn the carbon brush contact surface is not integral the thrust spring is broken etc Replace the carbon brushes as an assembly oo om Reset 7 Assemble in the reverse order of disassembly 5301543 SCRUBTEC 5458 545BL 5538 553BL BOOST 5 48 653B 653BL 651BCL 66181 545 553E 653E 9097062000 2 2009 06 SERVICE MANUAL BRUSHING SYSTEM BRUSH MOTOR DISASSEMBLY ASSEMBLY SCRUBTEC 5458 545BL 5538 553BL 6538 653BL Disassembly 1 Remove
92. sconnect the battery connector 12 SCRUBTEC 545E 553E 653E Remove the retaining plate 61 of the tank 40 Carefully lift the tank 40 Remove the screws A and recover the washers Remove the motor cover B Remove the filter C and the gasket D Remove the motor E or L the sound deadening pipe F and the sound deadening panel G SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL Disconnect the electrical connector H of the motor E SCRUBTEC 545E 553E 653E Disconnect the electrical connections J and K of the motor L Check the gasket l for efficiency and if necessary replace it Assembly 13 Assemble the components in the reverse order of disassembly and note the following If necessary clean the filter C before assembling it see the procedure in the relevant paragraph WARNING AN SCRUBTEC 545E 553E 653E When the maintenance repair procedure is completed the tank 40 must always be locked with the plate 61 5301556 SCRUBTEC 545B 545BL 553B 553BL BOOST 5 66 653B 65381 651BCL 661BL 545E 553E 653 9097062000 2 2009 06 SERVICE MANUAL ENGLISH RECOVERY WATER SYSTEM SQUEEGEE SPRING CHECK REPLACEMENT All models with aluminium squeegee Check 1 2 5 6 7 8 9 1 1 Assembly Assemble the springs by performing steps 5 to 11 in the reverse order 12 gt Drive the machin
93. ts for example 2 These numbers refer to the components indicated in these two nomenclature pages Refer to these pages whenever it is required to identify a component mentioned in the text 1 Control panel 2 Handlebar 8 Solution rear filler neck 9 Water removable filler hose optional 10 Squeegee lifting lowering lever 11 Deck lifting lowering pedal 11a Pedal position when deck is lifted 11b Pedal position when deck is lowered 13 Rear steering wheel 14 Front wheels on fixed axle 15 Squeegee vacuum hose 16 Recovery water drain hose 17 Solution drain and level check hose 18 Brush pad holder deck 19 Brush pad holder with pad 20 Solution tank 21 Recovery water tank 22 Recovery water tank cover 23 Can holder 25 Squeegee 26 Squeegee mounting handwheels 27 Squeegee balance adjusting handwheel 28 Machine straight forward movement adjusting handwheel 29 Machine forward speed adjusting handwheel 30 Recovery water tank cover open 31 Tank cover gasket 32 Cover movable retaining plate 33 Cover fixed retaining plate 34 Serial number plate technical data conformity certification 35 Squeegee bumper wheel 36 Vacuum grid with automatic shut off float 37 Solution front filler neck 38 Foam filter 39 Deck bumper wheel 40 Recovery water tank opened 41 Tank lifting handle 42 Lifted tank tie rod 43 Vacuum system motor cover 44 Vacuum system motor sound deadening filter 54
94. ver open 31 Tank cover gasket 32 Cover movable retaining plate 33 Cover fixed retaining plate 34 Serial number plate technical data conformity certification 35 Squeegee bumper wheel 36 Vacuum grid with automatic shut off float 37 Solution filler neck 38 Filter 39 Deck bumper wheel 40 Recovery water tank opened 41 Tank lifting handle 42 Lifted tank tie rod 43 Vacuum system motor cover 44 Vacuum system motor sound deadening filter 54 Solution filter 55 Solution tap 56 Solenoid valve 59 Power supply cable 60 Power supply cable holder 61 Recovery water tank retaining plate 62 Brush pad holder switch 63 Vacuum system switch 64 Counterweight 79 Hour counter optional 82 Washing water flow control switches 82a Flow increase switch 82b Flow decrease switch 82c Solution flow indicator SCRUBTEC 5458 545BL 5538 553BL BOOST 5 24 653B 653BL 651BCL 661BL 545E 553E 653E 9097062000 2 2009 06 SERVICE MANUAL ENGLISH MAINTENANCE MACHINE NOMENCLATURE SCRUBTEC 545E 553E Continues p lt J A 4 27 p d Leh JES f A 2 2 W A 772 82c 82 82b 5100145 5 SCRUBTEC 5458 54581 5538 55381 BOOST 5 653B 653BL 651BCL 661BL 545 553 653E an MAINTENANCE MACHINE NOMENCLATURE SCRUBTEC 653E Throughout this Manual you will find numbers in bracke
95. vn USA ALTO Cleaning Systems Inc Part of the Nilfisk Advance Group 12249 Nations Ford Road Pineville NC 28134 USA Tel 1 704 971 1240 Fax 1 704 971 1241 E mail info altocsi com Clarke 2100 Highway 265 Springdale AR 72764 USA Tel 1 479 750 8450 Fax 1 479 750 4540 E mail customerservice clarkeus com www ClarkeUS com Clarke American Sanders 2100 Highway 265 Springdale AR 72764 USA Tel 1 479 750 1000 Fax 1 479 750 4540 E mail customerservice americansanders com www AmericanSanders com American Lincoln 1100 Haskins Road Bowling Green OH 43402 USA Tel 1 419 352 7511 option 2 Fax 1 419 373 4221 E mail customerservice americanlincoln com www AmericanLincoln com
96. wer supply PET pressed and brush function activated EPI J3 MOLEX MINIFIT type 6 ways vertical o nly version 702 Electronic PIN Description board V ref Connected to in out ra M4 only for 1 Water pump power supply OUT 24V with key 41 706 OV pulsed according to water flow setting only with paddle M4 only for x Water pump power supply SET pressed and brush function activated 706 3 Solution pump power supply OUT 24V with key on I M5 OV pulsed as J3 2 when active squared wave with different 4 Solution pump power supply OUT frequencies according to the setting solution flow M5 5 B type deck configuration return IN 24V always with cylindrical brush deck installed CSC 2 6 Auxiliary power supply OUT 24V with key on CSC 1 45 SJT VH type 3 ways vertical only version CFBA702 Electronic PIN Description board V ref E in out o 1 Potentiometer solution flow adjusting OUT OV always with connected batteries RV3 1 2 22 490 solution flow adjusting IN 0 5V in accordance to the position of the potentiometer RV3 2 3 Potentiometer solution flow adjusting OUT with key on I RV3 3 98 SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL 545E 553E 653E 9097062000 2 2009 06 Nilfisk ALTO Why Compromise www nilfisk alto com HEADQUARTERS DENMARK Nilfisk Advance Group
97. witches RD Red ES2 Vacuum system relay VT Violet EV1 Water solenoid valve WH White F1 Deck fuse YE Yellow F2 Vacuum system fuse F3 Drive system fuse Signal circuit fuse F5 Brush pad holder release fuse F6 Pump fuse HM Hour counter optional K1 Ignition key M1 Brush pad holder motor M2 Vacuum system motor M3 Drive system motor M5 Detergent pump optional RV2 Maximum speed potentiometer RV3 Detergent potentiometer optional Swi Brush drive system enabling switch SW2 Reverse gear switch Only for machines with cylindrical brush deck Only for machines without on board battery charger q A RD RD RD RD RD RD F3 Fe ta qi gt 23 RD y We 9 W t QUA 3 m WH RD Yi VI 2 GN BK m NS JUS R yo 2 0 5 13 JIS nd fou EI u poun nh 5 BU WH JM TES gum u a BAT CH S gt aud GY el ce si e EVI L H Ji e M5 uc gs ese a ag a 0 Ju J8 BK BK BK BK BK BK l P100128 94 SCRUBTEC 545B 545BL 5538 553BL BOOST 5 9097062000 2 2009 06 653B 653BL 651BCL 661BL 545E 553E 653E SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM COMPONENT LAYOUT SCRUBTEC 545E 553E 653E Key C1 Suppression filter EB1 Water flow electronic board ES1 Brush motor relay EV1 Water solenoid valve F1 Electronic board fus
98. with optional hour counter 1 Connect power supply cable 59 to the electrical mains 2 Press the vacuum system switch 63 and read on the hour counter 79 the total number of working hours scrubbing drying performed by the machine 3 Turn off the vacuum system by pressing the switch 63 4 Disconnect the power supply cable 59 from the electrical mains and place it on the holder 50 POWER SUPPLY CABLE CHECK SCRUBTEC 545E 553E 653E Carefully check the power supply cable and the relevant plug for wear cuts cracks or other damages If the power supply cable or the relevant plug is damaged replace them with original spare parts BATTERY CHARGE AND MAINTENANCE models See the User Manual a SCRUBTEC 545B 545BL 5538 55381 BOOST 5 ki s t ak 06 653B 653BL 651BCL 661BL 545E 553E 653E dd ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM BATTERY DISASSEMBLY ASSEMBLY SCRUBTEC 545B 545BL 553B 553BL BOOST 5 653B 653BL 651BCL 661BL Disassembly If the tank 21 contains recovery water Drive the machine to the appointed recovery water disposal area Turn the ignition key 80 to 0 Empty the recovery water tank 21 with the hose 16 Drive the machine on a level floor Turn the ignition key 80 to 0 Disconnect the battery connector 12 Carefully lift the tank 40 Disconnect the cables A from the battery terminals Remove the battery shims if equipped

scrubtec 545b / 545bl / 553b / 553bl / boost 5 / 653b

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