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Service Manual

1. 1190 mm 46 85 in 890 35 100367 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH MAINTENANCE The lifespan of the machine and its maximum operating safety are ensured by correct and regular maintenance WARNING GENERAL INFORMATION Read carefully the instructions in the Safety chapter before performing any maintenance procedure The following tables provides 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 see the following paragraphs SCHEDULED MAINTENANCE TABLE Procedure Daily after using the machine Every six months Weekly Yearly Battery charging Squeegee cleaning Brush cleaning Tank debris collection grid and vacuum grid with float cleaning and cover gasket check EcoFlex system cleaning and draining optional Squeegee blade check and replacement Solution filter cleaning Vacuum system motor filter cleaning Battery WET fluid level check Screw and nut tightening check Electromagnetic brake efficiency check Brush pad holder motor carbon brush check or replacement Vacuum system motor car
2. 13 SOLENOID VALVE SOLUTION SYSTEM FILTER 5 13 TROUBLESHOOTING E 14 WIRING 14 22 3 lt 332 33 2 2 5 _ 15 DETERGENT PUMP AND ONE WAY VALVE 15 ECOFLEX SYSTEMIDISABLING PROCEDURE tinent ntt e e enu ede ecu c etae cen 16 TROUBLESHOOTING mM 16 BRUSHING SYSTEM 17 BRUSH PAD DECK DISASSEMBLY ASSEMBLY tette 17 BRUSH MOTOR ELECTRICAL INPUT 6 tree cta ciere rt d 18 BRUSH MOTOR CARBON BRUSH 20 BRUSH MOTOR DISASSEMBLY ASSEMBLY 2 trt teda rt a 21 BRUSH DECK LIFTING LOWERING ACTUATOR 22 BRUSH DECK ADJUSTER SPRING 5 5 23 BRUSH DECK DRIVE GUIDE 5 24 lcm 25 WIRING 26 RECOVERY WATER SYSTEM
3. 47 SCREW AND NUT TIGHTENING gt _ _ 47 FRONT FAIRING DISASSEMBLY ASSEMBLY e cccescccucsscesssccescccucesseccecuseccuseesscsersucersusecsusecsusessuceessecessececsesecasesecatsecastsssecerseces 47 38 54451 _________________ 49 MACHINE WORKING HOUR CHECK 49 CHARGE CONDITION DISPLAY 49 BATTERY TYPE SETTING WET OR 50 FUSE 1 FUNCTION ELECTRONIC BOARD LAY OUT AND DISASSEMBLY ASSEMBLY tente 52 DISPLAY ELECTRONIC BOARD AND DASHBOARD ELECTRONIC BOARD 53 TROUBLESHOOTING d RM LE eU M 54 55 RECORD OF ALARMS BATTERY MANAGEMENT PARAMETERS PARTIAL HOUR 57 DISPLAY OF CURRENT VALUES OF SIGNIFICANT VARIABLES HOUR COUNTERS AND STORED ALARMS 59 DISPLAY AND CHANGE OF PARAMETERS WHICH CAN BE SET BY THE USER e enne 60 00 61 0 0 0 gt gt M 63 VIII gt IM 0 2 MM nat kat he Ate T E 65
4. 2 9099052000 5 3000 26 Disc 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 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 that All covers are closed Theignition key is removed The machine is securely fastened to the means of transport OTHER REFERENCE MANUALS The following manuals are available at Nilfisk Literature Service Department SC3000 Operator manual Form Number 9098828000 SC3000 Spare Parts List Form Number 9098828000 24V 670W Motor Installation Instructions Form Number 9098456000 SAFETY The following symbols indicate potentially dangerous situations Always read this information carefully and take all necessary precautions 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
5. 27 VACUUM SYSTEM MOTOR ELECTRICAL INPUT 2 27 VACUUM SYSTEM MOTOR CARBON BRUSH 28 VACUUM SYSTEM MOTOR 29 SQUEEGEE LIFTING ACTUATOR DISASSEMBLY ASSEMBLY 30 SQUEEGEE LIFTING CABLE DISASSEMBLY ASSEMBLY 31 iie igzeelic E 32 WIRING LET 33 5 3000 26 Disc 9099052000 1 ENGLISH SERVICE MANUAL PARKING BRAKE SYSTEM cernerent nennen EE ___ __ _ 35 ELECTROMAGNETIC BRAKE DISASSEMBLY ASSEMBLY ttt tetti 35 EE NEN EL 36 37 T _ _ _ _ _ _ _ __ _ ___ 39 DRIVE SYSTEM MOTOR ELECTRICAL INPUT CHECK ettet 39 DRIVE SYSTEM MOTOR CARBON BRUSH 40 DRIVE SYSTEM 41 DRIVING WHEEL DISASSEMBLY ASSEMBLY ettet ttt ttt ttt tts btts 43 DRIVER S SEAT ttes 45 45 46 _
6. 2 Remove the brush deck see the procedure in the relevant paragraph 3 Turn the ignition key to 0 and disconnect the batteries 4 Disconnect the actuator connector see the function electronic board 5 Remove the screw A and recover nuts bushings and washers 6 Remove the screw B and recover the washer 7 Remove the actuator C A 8 ssembly Assemble the components in the reverse order of disassembly P100381 22 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH BRUSHING SYSTEM BRUSH DECK ADJUSTER SPRING DISASSEMBLY ASSEMBLY Disassembly 1 Drive the machine on a level floor 2 Remove the brush pad holder deck see the procedure in the relevant paragraph 3 Turn the ignition key to 0 and disconnect the batteries 4 Remove the front fairing see the procedure in the relevant paragraph 5 Place a wooden shim A under the deck holder assembly Wooden shim thickness must be 160 6 Unscrew the ring nut B recover the washer then carefully remove the spring C 7 If necessary replace the spring taking care to properly place the elastic ends D on the frame A 8 ssembly Assemble the components in the reverse order of disassembly and note the following e Tighten the ring nut B so that the deck holder assembly can turn freely 1 frm n M LS _ p P100382 5 3
7. Apply the amperometric pliers on one cable B of the batteries Turn the ignition key 58 to 47 Turn on the vacuum system by pressing the switch 63 and check that the motor electrical input is 16 19 A at 24 V Turn off the vacuum system motor by pressing the switch 63 Remove the amperometric pliers B If the electrical input exceeds the specifications check the motor carbon brushes see the procedure in the relevant paragraph If necessary remove 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 3 and 4 in the reverse order 5301553 5 3000 26 Disc 9099052000 27 ENGLISH SERVICE MANUAL RECOVERY WATER SYSTEM VACUUM SYSTEM MOTOR CARBON BRUSH CHECK REPLACEMENT Remove the vacuum system motor see the procedure in the relevant paragraph At the workbench remove the screws and the cover A from the vacuum system motor B Remove the screws C Disconnect 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
8. The function electronic board EB1 is faulty replace The wiring harness is damaged check all connections inside the electrical component compartment included those of the function electronic board The drive system motor carbon brushes are worn replace The drive system motor M3 is faulty replace The driver s seat microswitch is faulty repair replace The parking brake cannot be disengaged see the Parking Brake chapter There is an open in the function electronic board fuse F2 replace 0 The function electronic board EB1 is faulty see the Electrical System chapter FUNCTION ELECTRONIC BOARD ERROR CODES The function electronic board error codes indicate the drive system faults see the Function Electronic Board Error Codes paragraph PONS 50 09 41 0001 5 3000 26 Disc 9099052000 45 ENGLISH SERVICE MANUAL DRIVE SYSTEM WIRING DIAGRAM P100393A 46 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH OTHER SYSTEMS OTHER SYSTEMS SCREW AND NUT TIGHTENING CHECK 1 Drive the machine on a level floor with the recovery tank empty 2 the ignition key to 0 and disconnect the batteries 3 Carefully lift the tank assembly 4 Then check Tightening of mounting screws and nuts Correct position of fasteners Visible faults in the components Leaks 5 Carefully lower the tank assembly FRONT FAIRING DISASSEMBLY ASSEMBLY Disass
9. if ride on Maximum battery size Maximum brush and squeegee size e Full clean water tank Optional components installed e Weight on wheels checked Print on the floor checked on cement for each single wheel Result expressed as maximum value for front and rear wheels 6 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH GENERAL INFORMATION TECHNICAL DATA Continues Technical data for machines with brush pad holder deck Description SC3000 26 Disc Brush pad diameter 13 in 330 mm Weight without batteries and with empty tanks 385 8 Ib 175 kg Maximum weight with batteries full tanks and operator GVW 983 2 Ib 446 kg Hourly efficiency 2 5 mi h 4 km h 24488 ft 2 275 m Deck right left offset variable 0 3 9 1 0 0 100 mm 25 gt 0 mm Brush distance from the floor when lifted 1 9 in 48 mm Brush pad motor power 2 x 0 53 hp 2 x 400 W Brush pad holder speed 230 rpm Brush pad holder pressure with extra pressure function turned off 66 1 Ib 30 kg Brush pad holder pressure with extra pressure function turned on 105 8 Ib 48 kg 5 3000 26 Disc 9099052000 7 ENGLISH SERVICE MANUAL GENERAL INFORMATION DIMENSIONS 563000 26 Disc
10. to the dashboard electronic board 6 A Te Remove the screws 1 remove the display electronic board and recover the springs J of the microswitches ssembly Assemble the components in the reverse order of disassembly and note the following Install the display electronic board and check the proper operation of springs J microswitches and levers L and M Install the dashboard electronic board by carefully attaching it to the cover C and paying attention to the routing of the flat connections E and F in the cover slots P100398 563000 26 Disc 9099052000 53 ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM TROUBLESHOOTING See the other chapters related to the use of the electrical system Other possible causes 1 batteries are discharged or the connections are not efficient charge the batteries or clean the connections 2 The batteries are broken check the battery no load voltage NOTE 0 A damage to the battery charger or its connections can prevent the machine from operating properly 3 The battery charger is broken replace 4 There is an open in the fuses replace 5 wiring harness is cut or pressed or short circuited repair 54 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM FUNCTION ELECTRONIC BOARD ERROR CODES The function electronic board indicates a series of al
11. 563000 26 Disc 9099052000 35 ENGLISH SERVICE MANUAL PARKING BRAKE SYSTEM TROUBLESHOOTING The brake does not operate Possible causes 1 electromagnetic brake deactivation lever is turned to unlock position remove the shim 2 The braking masses are not efficient replace the electromagnetic brake The brake does not activate when pressing the forward reverse gear pedal Possible causes 1 There is an open in wiring harness between function electronic board and electromagnetic brake check repair the wiring harness electrical connections 2 The electromagnetic brake BRK is faulty replace 3 function electronic board 51 is faulty replace 36 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH WIRING DIAGRAM PARKING BRAKE SYSTEM P100389A 5 3000 26 Disc 9099052000 37 ENGLISH SERVICE MANUAL PARKING BRAKE SYSTEM 38 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH DRIVE SYSTEM DRIVE SYSTEM DRIVE SYSTEM MOTOR ELECTRICAL INPUT CHECK WARNING This procedure must be performed by qualified personnel only and with the help of an assistant Drive the machine on a level floor Apply proper wedges to rear wheels so that the machine cannot move when the front wheel is lifted Slightly lift the front part of the machine and apply to the frame brackets two proper wo
12. Disc 9099052000 31 ENGLISH SERVICE MANUAL RECOVERY WATER SYSTEM TROUBLESHOOTING The vacuum system motor does not turn on Possible causes 1 The wiring harness between function electronic board and vacuum system motor is damaged repair 2 The vacuum system motor carbon brushes are worn replace 3 The vacuum system motor is faulty check the electrical input 4 function electronic board ES1 is damaged replace Dirty water vacuuming is insufficient or there is no vacuuming Possible causes The vacuum grid with automatic shut off float is activated because the recovery tank is full empty the recovery tank The debris tray is clogged clean 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 O EO Or OUT The squeegee leaves lining on the floor or does not collect water Possible causes 1 There is debris under the blade remove 2 The 50066066 blade edges are torn or worn replace 3 The squeegee is not balanced adjust it with the relevant handwheel The squeegee does not lift lower Poss
13. and disconnect the batteries Under the driving wheel assembly disconnect the drive system motor and electromagnetic brake connections A Remove the electromagnetic brake see the procedure the relevant paragraph Remove the driving wheel assembly see the procedure in the relevant paragraph At the workbench with indelible pen mark the installation position of the motor on the gear box B Remove the screws C and carefully remove the drive system motor D Check the oil seal gasket E for wear In case of oil leaks between the drive system motor and the gear box replace the oil seal as indicated below seal replacement 9 Remove the screw F and recover the washer 10 Carefully remove the gear from the motor pin 1 11 Remove and replace the oil seal gasket H 12 Rub the pin 1 of the drive system motor with 400 grit sand paper Clean the pin with thinner 13 Apply Loctite 542 on the pin I and on the gear then install 14 Apply strong threadlock on the threads of the screw F then tighten the screw at 7 4 ftlbs 10 Nm Assembly 15 Assemble the components in the reverse order of disassembly and note the following Checkthe oil level in the hole J of the gear box If necessary top up with SAE 80W 90 oil Install the drive system motor on the gear box motor using the mark B as reference 5 3000 26 Disc 9099052000 41 ENGLISH SERVICE MANUAL DRIVE
14. It indicates the necessity to refer to the Operator manual before performing any procedure 563000 26 Disc 9099052000 3 ENGLISH SERVICE MANUAL GENERAL INFORMATION GENERAL INSTRUCTIONS Specific warnings and cautions to inform about potential damages to people and machine are shown below DANGER connector and remove the ignition key Before performing any maintenance repair cleaning or replacement procedure disconnect the battery This machine must be used by properly trained operators only Keep the battery away from sparks flames and incandescent material During the normal operation explosive gases are released Do not wear jewelry when working near electrical components Do 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 Battery charging produces highly explosive hydrogen gas Keep the tank assembly open during battery charging and perform this procedure in well ventilated areas and away from naked flames Carefully read all the instructions before performing any maintenance repair procedure WARNING 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 pull or carry the machine by the bat
15. Power supply connection and D Driving wheel connection M1 and 2 E Pressure switch module connection J7A and J7B e Electrical component wiring harness connection J1 G Foot board wiring harness connection J3 Frame wiring harness connection J2 I Vacuum system wiring harness connection VA and VA e J Recovery tank wiring harness connection J6 K Electromagnetic brake wiring harness connection J5 e L Brush deck actuator wiring harness connection J4 6 Remove the function electronic board mounting screws M from the plate Assembly 7 Assemble the components in the reverse order of disassembly A M B C D M 52 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM DISPLAY ELECTRONIC BOARD AND DASHBOARD ELECTRONIC BOARD REPLACEMENT Disassembly 1 Drive the machine on a level floor 2 the ignition key to 0 and disconnect the batteries 3 Unscrew the steering wheel height control lever 2 and disconnect the wiring harness connection A 4 Atthe workbench remove the screws B the cover C and recover the gasket D 5 Disconnect the flat connections E and of the display electronic board
16. SYSTEM DRIVE SYSTEM MOTOR DISASSEMBLY ASSEMBLY Continues P100391 42 9099052000 563000 26 Disc SERVICE MANUAL ENGLISH DRIVE SYSTEM DRIVING WHEEL DISASSEMBLY ASSEMBLY WARNING This procedure must be performed by qualified personnel only and with the help of an assistant 1 Drive the machine on a level floor 2 the ignition key to 0 and disconnect the batteries 3 Remove the machine foot board see the procedure in the relevant paragraph 4 Apply proper wedges to rear wheels so that the machine cannot move when the front side is lifted 5 Lift the front part of the machine and apply to the frame front sides two proper wooden shims high enough to keep the front wheel lifted for about 4 in 10 cm from the floor 6 Under the driving wheel assembly disconnect the drive system motor and electromagnetic brake connections 7 Remove the screws A and recover the washers 8 Carefully lower the driving wheel assembly with steering paying attention to the wiring harness B 9 Remove the screws C then remove the main gear D and the wiring harness shield E Note the wiring harness routing under the shield E for proper reassembly 10 Remove the screws F and remove the driving wheel G 11 Remove the screws H recover the washers and remove the wheel H Assembly 12 Assemble the components in the reverse order of disassembly and note the following Tighten the
17. alarm code description t3 Electromagnetic brake not present See alarm code description t5 Drive system power section damage See alarm code description t6 Pedal input not admitted See alarm code description t7 Drive system overcurrent See alarm code description t8 Drive system relay fault See alarm code description GB N Time of continuous use with discharged batteries im d KEY to switching off GC Charging cycle interrupted before completion disconnection before PHASE with red or GD N Charging phase duration M Number of hours from battery charger connection to completion of PHASE red LED on if 4 5 3000 26 Disc 9099052000 57 ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM BLACK BOX RECORD OF ALARMS BATTERY MANAGEMENT PARAMETERS PARTIAL HOUR COUNTER Continues EXAMPLE 1 Last stored alarm alarm G8 occurred when the machine working hours were 24h and 19m next to last stored alarm alarm F4 occurred when the machine working hours were 22h and 5m PROGRAMMER PROGRAMMER Logged alarm 1 ALL_G8 24h 19m Logged alarm 2 ALL F4 22h 55m P100399 EXAMPLE 2 Charging cycle interrupted before completion when the machine working hours were 15h and 45m last stored event PROGRAMMER GC 1 15h 45m 2lhours 31 min P100400 58 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH ALARMS 1 the
18. an open in the electrical connection replace the solenoid valve repair the electrical connection There is debris in the solution clean water tank clogging the output hole clean the tank There is debris in the solution clean water hoses clogging the flow clean the hoses The function electronic board 1 is faulty replace The display electronic board EB2 is faulty replace The dashboard electronic board EB3 is faulty replace The solution 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 WIRING DIAGRAM P100374A 14 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH ECOFLEX SYSTEM ECOFLEX SYSTEM DETERGENT PUMP AND ONE WAY VALVE DISASSEMBLY ASSEMBLY Disassembly Place the machine on a hoisting system if available then lift it Otherwise drive the machine on a level floor Lower the brush deck Turn the ignition key to 0 and disconnect the batteries Open the detergent tank plug 42 On the left side of the machine remove the screws and nuts A Disconnect the connectors B and C Disconnect the hose D Remove the detergent pump E If necessary remove the retaining springs F and disconnect the one way valve G from the relevant hoses Assembly 10 Assemble the components in the reverse order
19. ignition switch to 0 2 Open the electrical component compartment 3 4 the ignition switch to I 5 ELECTRICAL SYSTEM DISPLAY OF CURRENT VALUES OF SIGNIFICANT VARIABLES HOUR COUNTERS AND STORED Scroll with the UP and DOWN buttons the pages in the order shown in the table below 9 fe w E M1 M2 J8 J7A I zs J7B VA J6 J3 5 2 J2 4 6 Variable description Value meaning Software Release Software version loaded on the electronic board Supply Voltage Battery voltage V Ref Voltage Drive pedal input voltage V Drive Motor Voltage Drive Motor Current Drive system motor output voltage V Drive system motor current A Brushes Current Brush deck motor current mV Vacuum Current Vacuum system motor current A Heatsink Temp Temperature detected on the electronic board heatsink C Hour counter total TOTAL HOUR COUNTER h min Hour counter drive system DRIVE SYSTEM HOU
20. screws at 11 8 ftlbs 16 Nm When installing the driving wheel assembly the gears must be coupled with the straight wheel and the arrows J aligned as shown in the figure Tighten the screws and A at 16 21 ftlbs 22 Nm 5 3000 26 Disc 9099052000 43 ENGLISH SERVICE MANUAL DRIVE SYSTEM DRIVING WHEEL DISASSEMBLY ASSEMBLY Continues 1 100392 44 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH DRIVE SYSTEM DRIVER S SEAT SAFETY MICROSWITCH REPLACEMENT Disassembly Drive the machine on a level floor Turn the ignition key to 0 and disconnect the batteries Lift the recovery tank assembly 19 and remove the driver s seat mounting screws Disconnect the microswitch connector Lift the recovery tank cover 20 and remove the remaining driver s seat mounting screws Remove the driver s seat remove the wiring harness from the hole and then remove the driver s seat microswitch by peeling off the adhesive Assembly 7 Assemble the components in the reverse order of disassembly 8 Check that the machine cannot be stared when the operator is not on the driver s seat 17 TROUBLESHOOTING The machine does not move Possible causes The battery voltage is too low charge the battery The drive pedal potentiometer 4 is misadjusted or broken adjust or replace RV1
21. supply in 24V 120A BAT M1 Drive system motor out 24V 100A M3 M2 Drive system motor out 24V 100A M3 Vacuum system connections 2 ways male faston 6 3x0 8 pitch 6 5mm Ref Description Electronic board in out V ref max Connected to Vacuum system power supply out 0V M2 Vacuum system power supply out 10 24V 30A M2 J1 MOLEX MINIFIT type 12 ways vertical PIN Description Electronic board in out V ref max Connected to 1 Brush electromagnetic switch power supply out 24V 1A ES1 2 Brush electromagnetic switch power supply out 0V 1A ES1 3 Brush fuse voltage drop reading in 0V 1A F1 4 Brush fuse voltage drop reading in 0V 1A F1 5 Power supply for N A version configurator out 0V 1A J1 6 6 N A version configurator return in 0V 1A J1 5 7 Power supply for deck configurator out 0V 1A J1 8 8 Deck configurator return in 0V 1A J1 7 9 Consent for battery charger out 24V 1A CH 1 10 Enabling from battery charger in 24V 1A CH 2 11 Battery charger data communication slot in out 5V lt 1A CH 3 12 Auxiliary power supply under key out 24V lt 1A J2 MOLEX MINIFIT type 8 ways vertical PIN Description Electronic board in out V ref max Connected to 1 Solenoid valve power supply out 24V 1A EV1 2 Solenoid valve power supply out OV 1A EV1 3 Detergent pump power supply out 24V 1A 4 Detergent pump power supply out 0V 1A 5 Buzzer power supply out 24V 1A BZ1 PR1 6 Buzze
22. threshold 1 mV 30 50 90 2 Brush motor protection threshold 2 mV 30 60 90 DT Deck actuator m1 microswitch delay ms 0 0 10 SPT SPOT function timer s 60 300 DEADL Drive pedal bottom dead area V 0 0 0 9 1 5 DEADH Drive pedal top dead area V 0 0 2 2 2 5 FVMO Maximum forward speed 0 10 100 100 RVMO Maximum reverse speed 96 10 70 100 Maximum acceleration ramp s 0 5 3 0 5 0 DR Maximum deceleration ramp s 0 5 1 0 5 0 IR Maximum deceleration ramp on reversal s 0 5 0 5 5 0 BRK Electromagnetic brake activation delay s 0 5 1 0 5 0 INOM Drive system rated current A 10 20 30 IMAX Drive system maximum current A 10 80 100 TMAX Protection intervention time for IMAX s 0 15 60 AMAX Maximum lateral acceleration g 100 1 15 100 KG Lateral acceleration control constant 1 0 1 6 2 0 WSMIN not used WSMAX not used The default value is stored in the Electronic board by the manufacturer 60 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM CONNECTORS Power connections male RADSOK terminals 6mm AMPHENOL P N N01 060 0001 1 or equivalent Ref Description Electronic board in out V ref max Connected to Bt Electronic board power supply in 24V 120A BAT B Electronic board power
23. 000 26 Disc 9099052000 23 ENGLISH SERVICE MANUAL BRUSHING SYSTEM BRUSH DECK DRIVE GUIDE DISASSEMBLY ASSEMBLY Disassembly 1 Drive the machine on a level floor 2 Remove the brush pad holder deck see the procedure in the relevant paragraph and leave the deck holder assembly lifted 3 Turn the ignition key to 0 and disconnect the batteries 4 the steering wheel to accommodate the position of the drive guide A to be removed 5 Under the machine remove the screws B and the drive guide A 6 A i Replace the drive guide if it is too worn ssembly Assemble the components in the reverse order of disassembly e 40 P100383 24 9099052000 563000 26 Disc SERVICE MANUAL ENGLISH BRUSHING SYSTEM TROUBLESHOOTING Open circuit The fuse F1 determines an open in the supply circuit of the brush deck motors This system allows to prevent the circuits from being damaged under overload conditions The open in the fuse can be caused by the following 1 Short circuit in the brush motor wiring harness fault in the motor brushes do not turn Possible causes 1 The brush motor electromagnetic switch wiring harness is damaged repair 2 function electronic board 1 is faulty replace 3 The wiring harness between function electronic board EB1 and brush motor electromagnetic switch ES1 is damaged repair 4 The brush moto
24. 5 3000 26 Disc SERVICE MANUAL Advance models 9087267020 26 Disc EcoFlex Charger C Advance 9099052000 3 2011 07 SERVICE MANUAL ENGLISH TABLE OF CONTENTS GENERAL iei ule 3 5 6 00 0 0 3 MACHINE GIFTING Satire tecto 3 MACHINE TRANSPORTATION eh sash 3 OTHER REFERENCE E 3 3 SYMBOLS ean 3 GENERAL INSTRUCTIONS cem 4 TECHNICAL DATA 6 DIMENSIONS P 8 MAINTENANCE x 9 SCHEDULED MAINTENANCE TABLE 2 1 ert tei tee tet et crei cote aciei tasses eb vt 9 MACHINE NOMENCLATURE 10 SOLUTION CLEAN WATER SUPPLY SYSTEM
25. ICE MANUAL DRIVE SYSTEM DRIVE SYSTEM MOTOR CARBON BRUSH CHECK REPLACEMENT Check and replacement Drive the machine on a level floor Turn the ignition key to 0 and disconnect the batteries Remove the electromagnetic brake see the procedure in the relevant paragraph Remove the drive system motor see the procedure in the relevant paragraph At the workbench with indelible pen mark the installation position of the flange on the drive system motor A Remove the screws B the flange C and the plastic ring D Disengage the thrust spring E and remove the 2 carbon brushes F Check the carbon brushes for wear The carbon brushes are worn when the contact with the motor armature is insufficient the contact surface is not even the thrust spring is broken etc If necessary replace the carbon brushes Reset 9 Assemble the components in the reverse order of disassembly and note the following Clean with compressed air the area around the carbon brushes and the removed components Assemble the carbon brushes F with the cables G positioned as shown in the figure e Install the flange C on the drive system motor using the mark A as reference P100390 40 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH DRIVE SYSTEM DRIVE SYSTEM MOTOR DISASSEMBLY ASSEMBLY Disassembly QM OU BO Drive the machine on a level floor Turn the ignition key to 0
26. M STANDARD I II 9 919 3 LL 4 flashes of the yellow warning light GEL EXIDE type LOL I I III V g lig yp 4 LIE 5 2 flashes of the red warning light WET 5 re It El 2 flashes of the ing light GEL AGM REDUCED t green warning lig see note 6 IPSI of the yellow warning light GEL EXIDE type If the setting is to be changed perform the following procedure Turn off the machine by turning the ignition key A to 0 Press and hold the switches C and D at the same time then turn the ignition key A to I Release the switches C and D at least 5 seconds after starting the machine Within 3 seconds shortly press the switch D to go to the next setting 1 to 6 in cyclic sequence ooBRON NOTE 9 When performing steps 5 and 6 the settings shown on the display E too by the code in the table NOTE When using batteries with a capacity lower than 160Ah 5h in case of doubt refer to the battery documents to avoid battery overheating during charging procedure use the REDUCED charging current with setting 4 5 or 6 shown in the table according to the type of batteries installed NOTE 0 The battery charger optional must be set according to the type of batteries P100396 50 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH ELECTRICAL SY
27. R COUNTER h min Hour counter brushes Hour counter vacuum BRUSH HOUR COUNTER h min VACUUM SYSTEM HOUR COUNTER h min Logged Alarm N ALARM STORAGE possible Connect the ITALSEA programmer NILFISK P N 9097297000 to the function electronic board connector J9 A P100401 The value is the same as the voltage drop on the F1 fuse which is proportional to the current but does not have the same value in Amp See BLACK BOX paragraph 5 3000 26 Disc 9099052000 59 ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM DISPLAY AND CHANGE OF PARAMETERS WHICH CAN BE SET BY THE USER 5 5 4 55 gt Turn the ignition switch to 0 Open the electrical component compartment Connect the programmer to the function electronic board connector J9 see figure Turn the ignition switch to Press the MODE button Scroll the parameters with the UP and DOWN buttons to find the one to be changed Press the MODE button to enter the change mode the parameter starts to flash Change the value with the UP and DOWN buttons Store the new set value by pressing the MODE button FUNCTION ELECTRONIC BOARD PARAMETER Parameters which can be set through programming port J9 Code Description Min default max values VRID Vacuum system partial supply voltage V 10 16 20 1 Brush motor protection
28. STEM FUSE AND ELECTROMAGNETIC SWITCH CHECK REPLACEMENT ARONA Drive the machine on a level floor Turn the ignition key to 0 and disconnect the batteries Remove the screws and remove the electronic component compartment cover 43 Remove the mounting screws of the function electronic board assembly and remove it from the housing Check replace the following fuses e F1 50A fuse Brush motors e F2 100A MIDI fuse Function electronic board drive and vacuum system blade fuse Signal circuit F4 15A blade fuse Deck and squeegee lifting actuator Further move the function electronic board assembly to remove the electromagnetic switch ES1 Place the function electronic board assembly in its housing tighten the mounting screws and install the electronic component compartment cover 43 P100396 563000 26 Disc 9099052000 51 ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM FUNCTION ELECTRONIC BOARD LAY OUT AND DISASSEMBLY ASSEMBLY Disassembly 1 Drive the machine on a level floor 2 Turn the ignition key to 0 and disconnect the batteries 3 Remove the screws and remove the electronic component compartment cover 43 4 Remove the mounting screws of the function electronic board assembly and carefully remove it from the housing 5 Disconnect the following connections sequentially A and
29. STEM FILTER DISASSEMBLY ASSEMBLY Disassembly Place the machine on a hoisting system if available then lift it Otherwise drive the machine on a level floor Lower the brush deck Lower and remove the squeegee from the holder Turn the ignition key to 0 and disconnect the batteries On the right side of the machine remove the screws and nuts A Disconnect the connector B Disconnect the hose C and D Recover the whole assembly and at the workbench remove the solenoid valve E or the filter assembly F by disconnecting unscrewing the connecting fastening components NDOJI eO gt gt Assembly 9 Assemble the components in the reverse order of disassembly and note the following Before screwing the threaded fittings G clean them then apply Teflon tape according to the screwing direction When assembling the filter F the stamped arrow H must be tuned in the direction of the solution flow P100373 563000 26 Disc 9099052000 13 ENGLISH SERVICE MANUAL SOLUTION CLEAN WATER SUPPLY SYSTEM TROUBLESHOOTING Small amount of solution or no solution reaches the brush Possible causes 1 2 3 oos The tank filter optional is clogged dirty clean The solution filter is clogged dirty clean The solution tap is closed semi closed replace The solenoid valve EV1 is broken or there is
30. The last 20 events are stored When the total number of events is used up the next events overwrite the older ones The data are shown on the programmer display listed by decreasing order starting from the latest as DATUM HOUR 1 per page The UP and DOWN buttons are used to select 1 page at a time All the stored paged can be scrolled The info button shows the DATUM EVENT DESCRIPTION for the selected line DATUM EVENT DESCRIPTION Condition G2 EEPROM error See alarm code description G3 General thermal protection See alarm code description G4 Blown F2 fuse See alarm code description G5 Wrong KEY sequence See alarm code description G6 No signal from BATTERY CHARGER See alarm code description G7 Battery undervoltage See alarm code description G8 Serial communication error with dashboard electronic board See alarm code description G9 Battery voltage drop See alarm code description F2 Brush motor protection intervention See alarm code description F3 VACUUM SYSTEM overcurrent See alarm code description F4 DECK ACTUATOR position irregularity See alarm code description F5 VACUUM SYSTEM power section damage See alarm code description F6 PRESSURE SWITCH signal fault See alarm code description F7 VACUUM SYSTEM output short circuit See alarm code description F8 Function general relay fault See alarm code description t2 Drive system amperometric protection intervention See
31. Z1 Reverse gear warning buzzer horn GN Green C1 Battery connector GY Grey C2 Battery charger main connector C3 Battery charger sub connector PK Pink C4 Brush deck connector RD Red CH Battery charger VT Violet EB1 Function electronic board WH White EB2 Display electronic board YE Yellow Dashboard instrument electronic board ES1 Brush electromagnetic switch EV1 Solenoid valve FO Battery fuse F1 Brush deck fuse F2 Main electronic board fuse F3 Signal circuit fuse Actuator fuse K1 Ignition switch M1 1 2 Brush motor M2 Vacuum system motor M3 Drive system motor M4 Detergent pump M5 Brush deck actuator motor Brush deck actuator position 0 microswitch m1 Brush deck actuator position 1 microswitch m2 Brush deck actuator position 2 microswitch M6 Squeegee actuator motor PR1 Solution clean water level pressure switch RV1 Drive pedal potentiometer SW1 Driver s seat microswitch 5 3000 26 Disc 9099052000 65 ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM WIRING DIAGRAM Continues go VM P100403A 66 9099052000 5 3000 26 Disc Advance 14600 21st Avenue North Plymouth MN 55447 3408 www advance us com Phone 800 989 2235 Fax 800 989 6566 2011 Nilfisk Advance Inc A Nilfisk Advance Brand
32. 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 manually move the machine the electromagnetic brake must be disengaged After moving the machine manually engage the electromagnetic brake again Do not use the machine when the electromagnetic brake handwheel is screwed down When the machine is to be pushed for service reasons missing or discharged batteries etc the speed must not exceed 2 5 mi h 4 km h This machine cannot be used on roads or public streets Pay attention 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 56 brushes and pads supplied with the machine and those specified in the Operator manual Using other brushes or pads could reduce safety Incase 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 If parts must be replaced require ORIGINAL spare parts from an Authori
33. arms in case of malfunction of one or more systems and in case of abnormal conditions detected in the input signals The alarms are shown on the display 71 except F6 by 2 signs following each other AL and where XX is the alarm code see the descriptions in the following tables Also the alarms are repeated in case of display malfunction by the diagnostic LEDs yellow and red on the electronic board as described in the following tables General Alarms YELLOW LED RED LED FLASHING Alarm Code No of Meaning Condition Effect flashes G2 EEPROM error EEPROM error G3 General thermal protection Heatsink temperature gt 90 Function block 54 Blown F2 fuse gt 1 2 Function block G5 Wrong KEY sequence Wrong key sequence Function block G6 No signal from BATTERY CHARGER No signal from battery charger battery phase isnot G7 Undervoltage B gt THRESHOLD 2 for t gt 10 Function block G8 Serial communication error with dashboard No signal or decoding error No block electronic board Drive system electromagnetic G9 Battery voltage drop DeltaV neg gt 3V on battery voltage brake Block Function Alarms RED LED FLASHING Alarm Code No of Meaning Condition Effect flashes F2 BRUSH motor amperometric protection Voltage higher than the safety threshold Brush electromagnetic switeh output block F3 VACUUM SYSTEM amperomet
34. bon brush check or replacement Drive system motor carbon brush check or replacement 1 And after the first 8 working hours 5 3000 26 Disc 9099052000 ENGLISH SERVICE MANUAL GENERAL INFORMATION MACHINE NOMENCLATURE 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 you need to identify a component mentioned in the text 1 Steering wheel with control panel see the following 11 Bumper wheel paragraph 12 Solution filter 2 Steering wheel height control lever 13 Solenoid valve 3 Ignition key 14 Solution clean water tank opening closing valve 4 Drive pedal 15 Squeegee hook 5 Heel support height adjustment 16 Battery charger optional 6 Front steering driving and braking wheel 17 Seat 7 Electromagnetic brake unlocking lever 18 Squeegee blades assembly 8 Emergency push button 19 Dumping recovery tank assembly 9 Battery connector 20 Recovery tank cover 10 Brush pad holder deck P100370 10 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH MACHINE NOMENCLATURE Continues 21 22 23 Serial number plate technical data conformity certification Solution clean water tank Solution clean water tank filler plug with removable filler hose Recovery water drain hos
35. e Tank assembly stand Container with debris collection grid Vacuum grid with automatic shut off float Solution clean water draining adapter Solution clean water tap Squeegee Squeegee vacuum hose Squeegee bumper wheels GENERAL INFORMATION Squeegee support wheels Squeegee mounting handwheels Squeegee balance adjusting handwheel Vacuum system motor Vacuum system motor filter Battery connection diagram Batteries Battery caps Battery charger cable optional Detergent tank Electronic component compartment cover Lifted recovery tank assembly and driver s seat Only for machine with EcoFlex system optional 25 LESS 37 36 38 41 d tooo 4 Food 38 P100371 SC3000 26 Disc 9099052000 11 ENGLISH SERVICE MANUAL GENERAL INFORMATION MACHINE NOMENCLATURE Continues 51 Reverse gear activation deactivation lever Reverse gear LED indicator Detergent flow control switch Washing detergent flow control switch led indicator Mute function switch Mute function switch LED Horn switch Ignition key Solution flow increase switch Solution flow decrease switch Solution flow indicator Battery warning lights Green warning light charged battery Yellow warning light semi discharged battery Red warning light discharged battery Vac
36. ed to 1 Driving wheel brake power supply out 24V 1A BRK 2 Driving wheel brake power supply out OV 1A BRK J6 TYCO MODU1 type 6 ways vertical PIN Description Electronic board in out V ref max Connected to 1 Squeegee actuator power supply out 0 24V 8A M6 2 Squeegee actuator power supply out 0 24V 8A M6 Flashing light power supply out 24V lt 1A BE 4 4 microswitch float power 0V BE SW1 2 Return from driver s seat microswitch in OV lt 1A SW1 Return from float in 0V lt 1 2 97 PRESSURE SWITCH connector Berger type 3 3 ways vertical A1 Pressure switch power supply out 5V lt 1A Press A1 A2 Pressure switch power supply out ov lt 1A Press A2 A3 Press A3 B1 Press B1 B2 Pressure switch signal in 0 5V 1A Press B2 B3 Pressure switch signal in 0V lt 1 Press B3 J8 JUMPER 2 ways vertical J9 MOLEX MINIFIT type 4 ways vertical Connector for parameter programming 62 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM ELECTRICAL COMPONENT LAYOUT Key BAT 24 V battery box BE Flashing light optional BRK Electromagnetic brake BZ1 Reverse gear warning buzzer horn C1 Battery connector C2 Battery charger main connector C3 Battery charger sub connector C4 Brush deck connector CH Battery charger EB1 Function electronic board EB2 Display electron
37. embly Drive the machine on a level floor with the recovery tank empty Turn the ignition key to 0 and disconnect the batteries Unscrew the steering wheel screw A Remove the steering wheel assembly B disconnect the wiring harness connection Remove the cover C then remove the Seeger ring D Remove the caps the screws E and the steering wheel plate Disconnect the ignition switch wiring harness Remove the screws G recover the washers disconnect the wiring harness and then remove the drive pedal H Remove the adjustable heel support I and recover the spring J 10 Remove the caps the screws K on the machine front and recover the washers 11 Remove the caps the screws L on the machine foot board and recover the washers and the nuts 12 Carefully remove the front fairing M Assembly 13 Assemble the components in the reverse order of disassembly 5 3000 26 Disc 9099052000 47 ENGLISH SERVICE MANUAL OTHER SYSTEMS FRONT FAIRING DISASSEMBLY ASSEMBLY Continues gt OE 7 2 em 7 M P100394A 48 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM ELECTRICAL SYSTEM MACHINE WORKING HOUR CHECK 1 Turn the ignition key A to 2 first 2 seconds of machine operation the display B shows the total n
38. etting Ratio 1 400 1 33 Rear wheel diameter 9 8 in 250 mm Front wheel specific pressure on the floor 72 psi 0 5 N mm Rear wheel specific pressure on the floor 130 psi 0 9 N mm Front steering driving and braking wheel diameter 8 8 in 225 mm Vacuum system motor power 0 56 hp 420 W Drive system motor power 0 4 hp 300 W Maximum speed 3 7 mi h 6 km h Maximum gradient when working 2 1 14 Sound pressure level at workstation ISO 11201 ISO 4871 EN 60335 2 72 LpA 65 dB A 3 dB A Machine sound pressure level ISO 3744 ISO 4871 EN 60335 2 72 LwA 82 dB A Vibration level at the operator s arms ISO 5349 1 EN 60335 2 72 Vibration level at the operator s body ISO 2631 1 EN 60335 2 72 98 4 in s 2 5 m s 3 1 in s 0 8 m s Battery compartment size length x width x height 14 9 x 21 2 x 11 8 in 380 x 540 x 300 mm Battery type 4 x 6 V batteries 180 Ah C5 WET 4 x 6 V batteries 180 Ah C5 GEL AGM Standard batteries autonomy 2 5 3 5 hours Total electrical input 60A Machine height 46 8 in 1 190 mm Machine maximum length 53 5 in 1 360 mm Machine width without squeegee 26 4 in 670 mm Vacuum system circuit capacity 0 0098 MPa 1 000 mmH O Machines have been tested under the following conditions With operator 165 3 Ib 75 kg
39. ible causes 1 the Electrical System chapter function electronic board diagnosis 2 cable is broken replace 3 actuator is faulty replace 4 The actuator fuse F4 is open replace 32 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH RECOVERY WATER SYSTEM WIRING DIAGRAM 2 3 YE GN BK P100387A 563000 26 Disc 9099052000 33 ENGLISH SERVICE MANUAL RECOVERY WATER SYSTEM 34 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH PARKING BRAKE SYSTEM PARKING BRAKE SYSTEM ELECTROMAGNETIC BRAKE DISASSEMBLY ASSEMBLY Disassembly 1 Place the machine on hoisting system if available then lift it Otherwise drive the machine on a level floor 2 Lower the brush deck 3 Turn the ignition key to 0 and disconnect the batteries 4 the steering wheel to reach the electromagnetic brake 5 On the left side of the machine remove the screws A and disconnect the connector B 6 Remove the electromagnetic brake C A 7 ssembly Assemble the components in the reverse order of disassembly and note the following Before installing the electromagnetic brake C clean it with compressed air Install the electromagnetic brake with the lever D downwards 8 After installing the electromagnetic brake check the parking brake P100388
40. ic board EB3 Dashboard instrument electronic board ES1 Brush electromagnetic switch EV1 Solenoid valve FO Battery fuse F1 Brush deck fuse F2 Main electronic board fuse F3 Signal circuit fuse Actuator fuse K1 Ignition switch M1 1 2 Brush motor M2 Vacuum system motor M3 Drive system motor M4 Detergent pump M5 Brush deck actuator motor Brush deck actuator position 0 microswitch m1 Brush deck actuator position 1 microswitch m2 Brush deck actuator position 2 microswitch M6 Squeegee actuator motor PR1 Solution clean water level pressure switch RV1 Drive pedal potentiometer SW1 Driver s seat microswitch 563000 26 Disc 9099052000 63 SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM ELECTRICAL COMPONENT LAYOUT Continues yo 4 2 e lt 2 5 WB 2 55 D BRK 2 M3 04 RV1 SES X LI P100402A SC3000 26 Disc 9099052000 64 SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM WIRING DIAGRAM Key Colour codes BAT 24 V battery box BK Black BE Flashing light optional BU Blue BRK Electromagnetic brake BN Brown B
41. ing cycle as shown in the relevant paragraph of the Operator manual The pump M1 is broken or there is an open in the electrical connection replace the pump repair the electrical connection There is foreign material 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 detergent flow control switch is malfunctioning check that the LED 78 turns on if necessary replace the dashboard electronic board 7 The function electronic board EB1 is not set for the operation with EcoFlex system if equipped remove the jumper wire J4 in front of the electronic board 8 The function electronic board EB1 is faulty replace 9 The display electronic board EB2 is faulty replace 10 The dashboard electronic board EB3 is faulty replace detergent reaches the brush also when the machine is off Possible causes 1 The pump M1 is 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 The EcoFlex system does not work in the US mode but in the EU mode Possible causes 1 Check the GREEN bridge from pin 5 to pin 6 A of the connector J1 B it has not to be present if present switch off the machine and cut it The EcoFlex system does not turn on when pressing the switch 77 a
42. nd the LED 78 does not turn on To check the function electronic board remove the panel as shown in Function Electronic Board Disassembly Assembly paragraph steps 1 to 4 Possible causes 1 The function electronic board EB1 is not set for the operation with EcoFlex system if present remove the jumper wire 8 C behind of the electronic board 2 The dashboard electronic board EB3 is faulty replace 2 MEM eal 1 i 2441144 P100377A 16 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH BRUSHING SYSTEM BRUSHING SYSTEM BRUSH PAD HOLDER DECK DISASSEMBLY ASSEMBLY Disassembly Drive the machine on a level floor or on a lift platform to facilitate disassembly Remove the brushes as shown in the Operator manual Turn the ignition key 58 on 47 Pressing the switch 67 to lower the brush pad deck Turn the ignition key 58 to 0 Disconnect the red connector A Unplug the pipe B of the cleaning solution Unscrew the screw C and recover the nut Remove the safety pins D 10 Unscrew the nut E and recover the washer then remove the brush pad holder deck F Assembly 11 Assemble the components in reverse order of disas
43. oden shims high enough to keep the front wheel lifted for about 3 4 2 cm from the floor WARNING Pay attention to the rotation of the driving wheel when performing the following steps Use jumper wire to disable the driver s seat microswitch Apply the amperometric pliers on the positive cable red of the battery wiring harness Turn the ignition key 58 to I Drive the machine at the maximum forward speed by pressing the pedal 4 and check that the electrical input is 5 7 A at 24 V Release the pedal 4 Turn the ignition key 58 to 0 and remove the amperometric pliers 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 wheel rotation necessary check if the electromagnetic brake slows down the wheel when the drive system motor is operating remove the electromagnetic brake and repeat the electrical input check see the procedure in the relevant paragraph If necessary check the motor carbon brushes see the procedure the relevant paragraph If necessary 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 5 3000 26 Disc 9099052000 39 ENGLISH SERV
44. of disassembly and note the following e Connect the connector with black cable B and white cable C as shown in the figure Install the one way valve with the arrow turned in the direction of the detergent flow s oy P100375 Black White P100376 5 3000 26 Disc 9099052000 15 ENGLISH SERVICE MANUAL ECOFLEX SYSTEM ECOFLEX SYSTEM DISABLING PROCEDURE In order to permanently disable the EcoFlex system proceed as follows 1 off the machine by turning the ignition key 58 to 0 2 Lift the lever 69 then turn the ignition key 58 to I 3 Release the lever 69 at least 8 seconds after turning on the machine After this procedure the EcoFlex the lever cannot be operated again LED 70 off and the detergent concentration level is the one which has been set In order to re enable the system repeat the steps 1 to 3 NOTE a The permanent disabling of the EcoFlex system is stored into memory even after the machine is turned off TROUBLESHOOTING Small amount of detergent or no detergent reaches the brush Possible causes 1 The detergent flow percentage is too low check change the percentage as shown in the Operator manual 2 The hydraulic circuit upstream of the detergent pump is not triggered check if the hose is filled and if necessary perform one or more drain
45. r electromagnetic switch ES1 is damaged replace 5 The brush motor fuse F1 is open replace One brush does not rotate 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 and clean the brushes 3 The motor is faulty repair or replace 4 The wiring harness is damaged repair The brushes cannot be lifted lowered or the extra pressure function cannot be turned on Possible causes 1 the Electrical System chapter function electronic board error codes 2 The deck lifting lowering actuator M5 end of stroke microswitches are broken replace the actuator 3 The deck lifting lowering actuator M5 is broken replace 4 There is an open in the actuator wiring harness check the connections according to the procedures shown in the Electrical System chapter Troubleshooting paragraph 5 The actuator fuse F4 is open replace 6 The function electronic board EB1 is damaged replace 5 3000 26 Disc 9099052000 25 ENGLISH SERVICE MANUAL BRUSHING SYSTEM WIRING DIAGRAM CI RD RD RD BAT BK Cl P100384A 26 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH RECOVERY WATER SYSTEM RECOVERY WATER SYSTEM VACUUM SYSTEM MOTOR ELECTRICAL INPUT CHECK WARNING This procedure must be performed by qualified personnel only
46. r power supply out 0V lt 1 21 7 Auxiliary power supply under key out 24V 1A 8 Auxiliary power supply out 0V 1A J3 MOLEX MINIFIT type 10 ways vertical PIN Description Electronic board in out V ref max Connected to 1 Dashboard power supply out 24V 1A EB2 1 2 Dashboard serial in out 5V lt 1A EB2 2 3 Dashboard serial in out OV lt 1A EB2 3 4 Dashboard power supply out OV lt 1A EB2 4 5 Power supply for key circuit out 24V lt 1A K1 6 Return from key in 24V lt 1A K1 7 Pedal potentiometer power supply out 5V lt 1A RV1 F 8 Pedal potentiometer return In 0 5V lt 1A RV1 E 9 Pedal potentiometer power supply out OV lt 1A RV1 D 10 5 3000 26 Disc 9099052000 61 ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM CONNECTORS Continues J4 MOLEX MINIFIT type 6 ways vertical PIN Description Electronic board in out V ref max Connected to 1 Actuator power supply microswitch out 0V 1A M5 m0 1 2 2 Return from microswitch actuator mO in OV lt 1A M5 m0 3 Return from microswitch actuator m1 in OV lt 1A M5 m1 4 Return from microswitch actuator m2 in 0V lt 1 M5 m2 5 Deck actuator power supply out 0 24V 8A M5 6 Deck actuator power supply out 0 24V 8A M5 J5 MOLEX MINIFIT type 2 ways vertical PIN Description Electronic board in out V ref max Connect
47. replace the carbon brushes Replace the carbon brushes as an assembly 8 Assemble the components in the reverse order of disassembly N S301555 28 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH RECOVERY WATER SYSTEM VACUUM SYSTEM MOTOR DISASSEMBLY ASSEMBLY Disassembly If there is recovery water in the tank drain it Turn the ignition key to 0 and disconnect the batteries Lift the recovery tank 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 Disconnect the connector H of the motor E Check the efficiency of the gasket I and if necessary replace it 9 5 5 gt Assembly 10 Assemble the components in the reverse order of disassembly 5301556 5 3000 26 Disc 9099052000 29 ENGLISH SERVICE MANUAL RECOVERY WATER SYSTEM SQUEEGEE LIFTING ACTUATOR DISASSEMBLY ASSEMBLY Disassembly 1 Lower the squeegee 2 the ignition key to 0 and disconnect the batteries 3 the cable grommet A and remove it from the squeegee 4 Remove the screws B and recover the washers 5 Remove the screw C and recover the nut 6 Disconnect the connector D and remove the squeegee lifting assembly E 7 8 A 9 At the wo
48. ric protection vacuum system abnormal elecmical inputs Vacuum system block 30A for T gt 10s End of stroke microswitch configuration not F4 DECK ACTUATOR position irregularity plausible or end of stroke not reached within Deck actuator block 10 F5 VACUUM SYSTEM power section damage CC MOSFET Vacuum system block Water level visualisation missing F6 PRESSURE SWITCH signal fault Pressure switch Vout gt 4 0V water flow and detergent management fault F7 VACUUM SYSTEM output short circuit lt 2 50 Vacuum system block F8 Function general relay fault Always closed opened Function block All general and function alarms and their relevant effects remain until reset from KEY input In case of simultaneous errors the one with greater priority is shown first priority order is opposite to the number of flashes 5 3000 26 Disc 9099052000 55 ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM FUNCTION ELECTRONIC BOARD ERROR CODES Continues Drive system alarms YELLOW LED FLASHING Alarm Code and No of Meaning Condition flashes t2 Amperometric protection intervention lt rated current for gt protection time t3 Electromagnetic brake not present Res J5 1 J5 2 gt 1k t4 Pedal input activated by ignition J3 8 DEADL on ascend front J3 6 t5 Drive system power section damage CC MOSFET t6 Pedal input not admitted Res J3 7 J3 9 10k or J3 8 J3 7
49. rkbench remove the screw F recover the spacers and the nut Remove the squeegee lifting actuator G ssembly Assemble the components in the reverse order of disassembly 6 0 x y 1 P100385 30 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH RECOVERY WATER SYSTEM SQUEEGEE LIFTING CABLE DISASSEMBLY ASSEMBLY Disassembly 1 2 3 Ass 4 5 6 7 Remove the squeegee lifting assembly see the previous paragraph steps 1 to 6 At the workbench remove the screw A and recover the nut Carefully remove the squeegee lifting cable B from the pulleys embly Install the lifting cable and note the following Grease the cable along its entire length with AGIP GR 30 or equivalent grease Insert the cable in the direction shown by the arrow Route the cable in the pulleys D E and F in sequence Fasten the cable grommet with the screw A and nut The components must be carefully installed as shown in the figure for the proper operation of the lifting system Install the squeegee lifting assembly see the previous paragraph Check the proper operation of the squeegee lifting system NOTE 8 The squeegee lifting system pulleys self lubricating and do not require maintenance P100386 563000 26
50. rushes E 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 5 f necessary disconnect the connections F and remove the carbon brushes with their supports and replace them Replace the carbon brushes as an assembly Reset 6 Assemble the components in the reverse order of disassembly and note the following When connecting the terminals F take care of their insulation from the surrounding parts of the frame 5301327 20 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH BRUSHING SYSTEM BRUSH MOTOR DISASSEMBLY ASSEMBLY 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 e ssembly Assemble the components in the reverse order of disassembly NOTE e For further information on deck components see the Spare Parts List P100378 563000 26 Disc 9099052000 21 ENGLISH SERVICE MANUAL BRUSHING SYSTEM BRUSH DECK LIFTING LOWERING ACTUATOR DISASSEMBLY ASSEMBLY Disassembly 1 Lower the brush deck
51. sed Dealer or Retailer Toensure 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 Do not wash the machine with direct or pressurised water jets or with corrosive substances When WET batteries are installed on the machine do not tilt the machine for more than 30 from the horizontal plane to prevent the highly corrosive acid from leaking out of the batteries If the machine must be tilted to perform any maintenance procedure remove the batteries 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 Scrapping chapter 563000 26 Disc 9099052000 5 ENGLISH SERVICE MANUAL GENERAL INFORMATION TECHNICAL DATA General technical data Description SC3000 26 Disc Cleaning width 26 in 660 mm Squeegee width 35 in 890 mm Solution clean water tank capacity 21 US gal 80 L Solution flow da 0 26 a 0 8 US gal min from 1 to 3 L min Recovery tank capacity 21 US gal 80 L Minimum maximum solution flow with and without EcoFlex system 0 0 8 US gal min 0 L min EcoFlex system solution tank capacity 1 3 US gal 5 L EcoFlex system detergent flow s
52. sembly 3000 26 Disc 9099052000 17 ENGLISH SERVICE MANUAL BRUSHING SYSTEM BRUSH MOTOR ELECTRICAL INPUT CHECK WARNING This procedure must be performed by qualified personnel only Drive the machine on a level floor Remove the brushes as shown in the Operator manual Place two wooden shims A under the brush deck sides B as shown in the figure Wooden shim thickness must be 1 in 25 mm WARNING Keep the wooden shims at an appropriate distance from the brush hubs 11 Use a jumper wire to disable the driver s seat microswitch Disconnect the driving wheel connector to disable the drive system Turn the ignition key 58 to I Lower the brush pad holder deck by pressing the switch 67 Apply the amperometric pliers E on one cable F of the right motor or on one cable of the left motor I Turn on the brushes by pressing the drive pedal 4 then check that the electrical input of the right or left motor 1 is as follows e 304 A at 24V for the brush pad holder deck motors Turn off the brushes by releasing the drive pedal 4 and lift the brush pad holder deck by pressing the switch 67 Turn the ignition key 58 to 0 Remove the amperometric pliers A If the electrical input is higher perform the following proced
53. t7 Overcurrent motor D C I gt 1 5 IMAX 18 Drive system relay fault Contacts always opened closed All the drive system alarms activates to cut off the power supply to the driving wheel motor not to the ELECTROMAGNETIC BRAKE until reset from KEY input except alarm t4 which is reset as soon as J3 8 DEADL In case of simultaneous errors the one with greater priority is shown first priority order is opposite to the number of flashes Other alarm indications on the display DISPLAY Meaning Condition 2 gt T Pressure switch module signal 4 0V Water level signal missing or as specified or floating Serial communication problem between dashboard electronic 888 Signal missing or errors board and function electronic board Off Dashboard electronic board power supply missing J1 1 J1 4 12V 56 9099052000 SC3000 26 Disc SERVICE MANUAL ENGLISH ELECTRICAL SYSTEM BLACK BOX RECORD OF ALARMS BATTERY MANAGEMENT PARAMETERS PARTIAL HOUR COUNTER The data indicated in the following table ALARMS BATTERY MANAGEMENT DATA are stored in the non volatile memory of the electronic board and can be recalled and displayed by the external programmer ITALSEA UNIVERSAL PROGRAMMER NILFISK P N 9097297000 connect to port J9 For each stored datum event the value HOURS MINUTES of the TOTAL hour counter is associated when the alarm occurred
54. tery 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 use the machine if the battery charger cable or plug is damaged If the machine is not working as it should has been damaged left outdoors or dropped into water return it to the Service Center 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 Do not smoke while charging the batteries To avoid any unauthorised use of the machine remove the ignition key Do not leave the machine unattended without being sure that it cannot move independently 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 as shown in this Manual Do not allow to be used as a toy Close attention is necessary when used near children Use only as shown in this Manual Use only Nilfisk s recommended accessories Take all necessary precautions to pre
55. umber of working hours ignition key to 41 performed by the machine 3 Turn the ignition key A to 0 It is possible to check the working hours performed by the machines through specific hour counters for DRIVE SYSTEM BRUSHES VACUUM SYSTEM see Display of Current Values of Significant Variables Hour Counters and Stored Alarms paragraph CHARGE CONDITION DISPLAY TRANSITION THRESHOLD VOLT INDICATION CONSEQUENCE WET GEL 1 GREEN LED fixed YELLOW LED fixed 22V 22 2 V 2 YELLOW LED fixed RED LED flashing 20 4 V 21 6 V Brushes OFF 3 Safety threshold 19 4 V 20 6 V Vacuum system OFF 4 Drive threshold 18 4 V 19 6 V Drive system OFF 5 3000 26 Disc 9099052000 49 ENGLISH SERVICE MANUAL ELECTRICAL SYSTEM BATTERY TYPE SETTING WET OR GEL AGM Set the electronic board of the machine and the battery charger optional according to the type of batteries installed WET or GEL AGM as shown below 1 Tum the ignition key A to I and in the very first seconds of machine operation detect the current setting by counting the number of flashes of the battery warning lights B as shown in the following table SETTING DISPLAY E BATTERY WARNING LIGHT INDICATION B BATTERY TYPE CHARGING CURRENT 1 LIH 4 flashes of the red warning light WET 2 re 4 flashes of the green warning light GEL AG
56. ures to detect and correct the abnormal input NOTE 0 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 dirt ropes cables etc on the brush hubs e Check the motor carbon brushes see the procedure in the relevant paragraph e Remove the motors see the procedure in the relevant paragraph and check the condition of all components If the above mentioned procedures do not lead to a correct electrical input the motors must be replaced see the procedure in the relevant paragraph Reset 12 Connect the driving wheel connector 13 Remove the jumper wire and enable the driver s seat microswitch 14 Remove the wooden shims and install the brushes 18 9099052000 563000 26 Disc ENGLISH SERVICE MANUAL BRUSHING SYSTEM BRUSH MOTOR ELECTRICAL INPUT CHECK Continues 5301326 19 9099052000 SC3000 26 Disc ENGLISH SERVICE MANUAL BRUSHING SYSTEM BRUSH MOTOR CARBON BRUSH CHECK REPLACEMENT Check 1 Remove the brush pad holder deck 2 Remove dust and dirt from the motor carbon brush support area A 3 Disengage the fasteners B and C then remove the four carbon brush supports A If necessary disconnect the electrical connections D 4 Check the carbon b
57. uum system switch Vacuum system led indicator Extra pressure switch Extra pressure led indicator Brush pad holder deck and squeegee lifting lowering Switch 72 68 69 70 71 e 72 Brush pad holder deck and squeegee lifting lowering LED indicator EcoFlex activation deactivation lever EcoFlex system LED indicator LED EcoFlex system on LED flashing EcoFlex system override Hour counter and solution level display When the machine is started it displays for a few seconds the number of working hours which have been performed While using the machine it displays the solution washing water level in the tank in gallons When the level is above 18 USgal the display indicates FUL When the level is under 4 USgal the display indicates LO When the tank is almost empty LO starts flashing NOTE The display could indicate LO even if the tank is not completely empty thus allowing to complete the cleaning cycle in any case it is recommended to check the actual solution fl ow supplied to the brushes Anti skid control activation LED indicator Only for machine with EcoFlex system optional 52 P100372 12 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH SOLUTION CLEAN WATER SUPPLY SYSTEM SOLUTION CLEAN WATER SUPPLY SYSTEM SOLENOID VALVE SOLUTION SY
58. vent hair jewelry and loose clothes from being caught by the machine moving parts 4 9099052000 5 3000 26 Disc SERVICE MANUAL ENGLISH GENERAL INFORMATION WARNING Do not use the machine on incline Do nottilt the machine more than the angle indicated on the machine itself in order to prevent instability Do not use the machine in particularly dusty areas Use the machine only where a proper lighting is provided Ifthe machine is to be used where there are other people besides the operator it is necessary to install the pivoting light and the reverse gear buzzer optional 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 The machine working temperature must be between 32 F and 104 F 0 C and 40 C The machine storage temperature must be between 32 F and 104 F 0 and 40 The 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 Incase of fire use

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