Advance SC750, SC800, SC750 ST, SC800 ST Service Manual
Form Number: 56043150
Revision: 11/10 Revised 12/16
General Information
Service Manual Purpose and Application
This Service Manual is intended for professional service technicians. It provides information on machine operation, component locations, basic troubleshooting, maintenance, and mechanical service procedures. The manual covers Nilfisk SC800 models and Advance SC750, SC800, SC750 ST, and SC800 ST models. It is crucial to compare the machine's model number on its nameplate with the numbers listed on the cover page to ensure the correct manual is being used.
Conventions: Directional terms (forward, backward, front, rear, left, right) are defined from the operator's perspective when in the driving position.
Transporting the Machine
CAUTION!
Before transporting the machine on an open truck or trailer, ensure it is securely tied down and all access doors and covers are secured.
Towing
CAUTION!
If towing or pushing is necessary, ensure the Key Switch is OFF. Move the machine at a normal walking pace (2-3 mph / 3-5 kph) for short distances only. Disconnecting the wheel drive motor wiring connector can make towing easier.
Cautions and Warnings
Nilfisk-Advance uses symbols to indicate potentially dangerous conditions:
- DANGER!: Warns of immediate hazards causing severe personal injury or death.
- WARNING!: Calls attention to situations that could cause severe personal injury.
- CAUTION!: Calls attention to situations that could cause minor personal injury or damage to the machine or property.
Read all instructions before use.
General Safety Instructions
Specific cautions and warnings are provided throughout the manual to prevent machine damage and bodily harm. Key safety points include:
- Only use by trained and authorized personnel.
- Caution on ramps/inclines: avoid sudden stops, sharp turns, use low speed downhill, clean while ascending.
- Keep sparks, flame, and smoking materials away from batteries due to explosive gases.
- Charge batteries in well-ventilated areas away from open flame; do not smoke while charging.
- Remove jewelry when working near electrical components.
- Turn key switch OFF and disconnect batteries before servicing electrical components.
- Never work under a machine without safety blocks or stands.
- Do not dispense or operate near flammable cleaning agents or liquids.
- Do not clean with a pressure washer.
- Do not operate on ramps or inclines exceeding 2% gradient.
- Use only specified brushes; others may impair safety.
- Machine is not approved for public paths or roads.
- Machine is not suitable for hazardous dust.
- Use care with scarifier discs and grinding stones.
- Ensure third parties, especially children, are not endangered.
- Read all instructions before performing service functions.
- Do not leave the machine unattended without turning off the key switch, removing the key, and securing the machine.
- Turn key switch OFF and remove key before changing brushes or opening access panels.
- Prevent hair, jewelry, or loose clothing from catching in moving parts.
- Use caution in below freezing temperatures; water in tanks/lines can freeze and cause damage. Flush with windshield washer fluid.
- Dispose of batteries according to local environmental regulations.
- Do not use on surfaces exceeding marked gradient.
- Ensure all doors and covers are positioned as indicated before use.
General Machine Description
The SC series machines (SC750, SC800, SC750 ST, SC800 ST) are battery-powered walk-behind floor scrubbers designed for flat, hard surfaces. They operate on a 24-volt system. Each machine has a controller for scrub and vacuum functions and another for the drive system. They can be equipped with either a Disc or Cylindrical scrub deck.
Nameplate
The nameplate provides essential identification information: Model (Name), Part No. (Model Number), and Serial Number, which are needed for ordering parts.
Know Your Machine
Control Panel SC750 and SC800 (Membrane Switch Control Panel)
These models feature a control panel with an LCD display. Key components include:
- Key Switch (Main Power): Turns power ON ('I') or OFF ('O').
- Solution ON/OFF Switch: Controls the flow of cleaning solution.
- Solution Increase Switch: Increases solution flow rate.
- Solution Decrease Switch: Decreases solution flow rate.
- Detergent ON/OFF Switch: Controls detergent flow for models with the EcoFlex system.
- Display Panel: Provides additional machine operation information via an LCD.
- Scrub ON/OFF Switch: Raises/lowers the scrub head assembly and enables/disables vacuum, solution flow, and scrub motors.
- Scrub Pressure Increase Switch (Disc models only): Applies additional scrubbing pressure.
- Scrub Pressure Decrease Switch (Disc models only): Returns to normal scrub pressure.
- Burst of Power Switch: Temporarily increases scrubbing power (optional detergent mixing system).
- Brush Remove Switch (Disc Decks Only): Initiates a sequence to remove brushes.
- Vacuum/Wand Switch: Starts and stops the vacuum motor.
LCD Display
The LCD display shows:
- F1: Hour Meter
- F2: Solution Tank Level Indicator
- F3: Fault Codes
- F4: Detergent Indicator (if equipped)
- F5: Detergent Ratio Indicator (if equipped)
- F6: Battery Indicator
- F7: Recovery Tank FULL Indicator
- F8: Battery Low Indicator
Indicator Lights
Indicator lights illuminate for 2 seconds upon key activation. They show:
- Solution Flow Indicators: Indicate low, medium, or high flow.
- Scrub Pressure Indicators: Indicate regular or extreme scrub pressure.
- Vacuum Indicator: Shows if the vacuum is on or off; flashes for timed delay shutoff.
- Detergent Indicator: Shows if detergent is on or off.
- Burst of Power Indicator: Shows if the switch is enabled or flashing yellow during use.
Control Panel SC750 ST and SC800 ST (Toggle Switch Control Panel)
These models use a control panel with three large toggle switches and no LCD display. Key components include:
- Key Switch (Main Power): Turns power ON ('I') or OFF ('O').
- Solution Switch (Low, Medium & High): Pressing forward turns on/increases solution flow; pressing backward turns off/decreases flow. Solution only flows when the machine moves.
- Vacuum/Wand Switch: Pressing forward turns on the vacuum motor; pressing backward turns it off.
- Scrub Switch:
- Cylindrical Models: Forward lowers deck and enables functions; backward disables functions and raises deck.
- Disc Models: Forward enables functions; further forward engages 'extreme' pressure and increases solution flow. Backward retracts to 'normal' pressure and decreases solution flow. Further backward disables functions and raises deck.
Indicator Lights
Indicator lights illuminate for 2 seconds upon key activation. They show:
- Solution Flow Indicators: Indicate low, medium, or high flow.
- Scrub Pressure Indicators: Indicate regular or extreme scrub pressure.
- Vacuum Indicator: Shows if the vacuum is on or off; flashes for timed delay shutoff.
- Battery Indicator: Shows battery condition (Green=Full, Yellow=Medium, Red=Low, Flashing Red=Low Voltage Cut Out Mode).
- Fault Code Indicator: Off for normal operation, flashes for code display. Lights up if key is on during charging. Displays selected setting in hidden menu.
Machine Specifications SC750 and SC750 ST
| Model Name/Model Number | SC750 | SC 750 ST |
|---|---|---|
| Machine Voltage | 24V | 24V |
| Battery Capacity | 242, 310, 312 Ah | 242, 310, 312 Ah |
| Solution Tank Capacity | 21.33/80.7 Gal/L | 21.61/78.0 Gal/L |
| Recovery Tank Capacity (Static) | 61 dB(A) | 61 dB(A) |
| Sound Pressure Level (IEC 60704-1) | 61 dB(A) | 61 dB(A) |
| Gross Weight | 942 lbs. (427.3 kg) | 942 lbs. (427.3 kg) |
| Net Weight | 347 lbs (157.4 kg) | 347 lbs (157.4 kg) |
| Static Wheel Pressure (right front) | 59.08 psi / .407 N/mm2 | 59.08 psi / .407 N/mm2 |
| Static Wheel Pressure (left front) | 60.1 psi /.414 N/mm2 | 60.1 psi /.414 N/mm2 |
| Static Wheel Pressure (center rear) | 287.6 psi (1.983 N/mm2) | 287.6 psi (1.983 N/mm2) |
| Vibrations at Hand Controls (ISO 5349-1) | .09 m/s2 | .09 m/s2 |
| Gradeability - Scrubbing and Transport (Full) | 14.9% (8.5°) | 14.9% (8.5°) |
| Gradeability - Trailer Ramp (Empty) | 17.6% (10.0°) | 17.6% (10.0°) |
Machine Specifications SC800 and SC800 ST
| Model Name/Model Number | SC 800 | SC800 ST |
|---|---|---|
| Voltage, Batteries | 24V | 24V |
| Battery Capacity | 242, 310, 312 Ah | 242, 310, 312 Ah |
| Solution Tank Capacity | 24.69 gal (93.5 l) | 24.69 gal (93.5 l) |
| Recovery Tank Capacity (Static) | 26.84 gal (101.6 l) | 26.84 gal (101.6 l) |
| Sound Pressure Level (IEC 60704-1) | 61 | 61 |
| Gross Weight | 996 lbs (451.77 kg) | 996 lbs (451.77 kg) |
| Net Weight (28" disc) | 363 lbs (169.2 kg) | 363 lbs (169.2 kg) |
| Net Weight (34" disc) | 365 lbs (170.1 kg) | 365 lbs (170.1 kg) |
| Net Weight (cylindrical) | 373 lbs (173.7 kg) | 373 lbs (173.7 kg) |
| Static Wheel Pressure (right front) | 71.0 psi / .490 N/mm2 | 71.0 psi / .490 N/mm2 |
| Static Wheel Pressure (left front) | 66.6 psi /.459 N/mm2 | 66.6 psi /.459 N/mm2 |
| Static Wheel Pressure (center rear) | 287.6 psi (1.983 N/mm2) | 287.6 psi (1.983 N/mm2) |
| Vibrations at Hand Controls (ISO 5349-1) | .09 m/s2 | .09 m/s2 |
| Gradeability Transport | 2% (1.15°) | 2% (1.15°) |
| Gradeability Cleaning | 2% (1.15°) | 2% (1.15°) |
Machine Maintenance
Regular maintenance is essential for optimal performance and longevity. Key maintenance items and their recommended frequencies are:
| Maintenance Item | Daily | Weekly | Monthly | Yearly |
|---|---|---|---|---|
| Charge Batteries | X | |||
| Check/Clean Tanks & Hoses | X | |||
| Check/Clean/Rotate Brushes/Pads | X | |||
| Check/Clean Squeegee | X | |||
| Check/Clean Vacuum Shut-Off Float | X | |||
| Empty/Clean Debris Tray in Recovery Tank | X | |||
| Clean Hopper on Cylindrical System | X | |||
| Check Each Battery Cell Water Level (not for gel cells) | X | |||
| Inspect Scrub Housing Skirts | X | |||
| Inspect and clean Solution Filter | X | |||
| Clean Solution Manifolds on Cylindrical System | X | |||
| Purge Detergent System (EcoFlex only) | X | |||
| Lubricate the Machine | X | |||
| *Check Carbon Brushes | X | |||
| Replace Isolators (REV only) | X |
*Check Carbon Brushes: Vacuum motor brushes (Qty 2) annually or after 300 hours. Brush and wheel drive motor brushes (Qty 4 per motor) annually or after 500 hours. Original length is 1" (25.4mm). Replace when shorter than 3/8" (9.5mm). Failure to service carbon brushes may result in motor damage not covered by warranty.
Lubricating the Machine
Apply light machine oil monthly to:
- General Pivot Points for Squeegee Linkage
- Squeegee mount angle adjustment knob threads
- Squeegee Tool end wheels
- General Pivot Points for Brush Linkage
- Scrub deck bumper wheels
Grease quarterly the Rear Caster Wheel Swivels.
CAUTION!
Turn the key switch off and disconnect the batteries before servicing the machine.
Chassis System
Functional Description
The chassis is constructed from heavy gauge steel and supports the drive transaxle, caster wheel, brush deck, squeegee assembly, and the machine body.
Control System
Functional Description
The machine utilizes two controllers: a Main Machine Controller and a Drive Motor Controller. The Main Machine Controller manages cleaning functions (scrub, solution, vacuum) based on operator input and other signals. It is located behind the operator control panel and supports fault code storage/display, programming mode, and service test mode. The Drive Motor Controller (Speed Controller) manages the drive motor for propulsion based on operator requests.
Component Locations
Key components include the Electrical Panel Cover, Circuit Breaker Mounting Plate, Control Switch Interface Panel, and the Main Machine Controller.
Troubleshooting
Fault Codes
SC750 and SC800 models: Error codes are displayed on the LCD screen. SC750 ST and SC800 ST models: Faults are indicated by blink codes on the fault code indicator light (two-digit codes: first digit flashes, short pause, second digit flashes, long pause). Multiple codes repeat in sequence.
Fault Code Table
| LCD Display Code | ST Blink Code | Code Definition | Explanation / Code Setting Conditions / Flash Indicator / Disables / Check |
|---|---|---|---|
| 3 | 1,1 | Drive Motor Controller Fault | Drive Motor Controller detected a problem and set a 'Trip Code'. Trip codes are grouped into 'Trip Types'. For Non-ST models, count Detergent LED flashes for Trip Type. For ST models, count High Solution Flow LED flashes. Refer to Wheel System, Traction chapter for details. |
| 4 | 1,2 | Scrub Deck Lift Actuator Circuit Over Current | Excessive current draw sensed (approx. 5.8 amps or more). Disables: Detergent, Solution, Brush Motors. Check for shorted actuator, mechanical binding, shorted wiring. |
| 5 | 1,3 | Brush Motor Circuit Over Current | Excessive current draw sensed (approx. 60 amps or more). Disables: Brush Head Actuator. Check for shorted motor, mechanical binding, current sense wire connections, ground connections. |
| 7 | 1,4 | Vacuum Motor Circuit Over Current | Excessive current draw sensed (approx. 25 amps or more). Check for shorted motor, current sense wire connections, ground connections. |
| 8 | 1,5 | Solution Solenoid Circuit Over Current | Excessive current draw sensed (approx. 0.7 amps or more). Check for shorted solenoid winding, shorted wiring. |
| 9 | 2,1 | Vacuum Contactor Coil Circuit Over Current | Excessive current draw sensed (approx. 0.1 amps or more). Check for shorted contactor winding, shorted wiring. |
| 10 | 2,2 | Brush Contactor Coil Circuit Over Current | Excessive current draw sensed (approx. 0.7 amps or more). Check for shorted contactor winding, shorted wiring. |
| 11 | (N/A) | Detergent Pump Circuit Over Current | Excessive current draw sensed (approx. 0.1 amps or more). Check for shorted pump winding, shorted wiring. |
| 12 | (N/A) | Brush Remove Contactor Coil Over Current | Excessive current draw sensed. Check for shorted contactor winding, shorted wiring. |
| 30 | 2,3 | Solution Solenoid Circuit Open | Controller energized solenoid but sensed no current flow (<= 20mAmps for 5 sec). Check for open solenoid winding, open wiring. |
| 31 | 2,4 | Brush Motor Circuit Open | Controller energized brush contactor but sensed no current flow through ground circuit (Senses <= 4 Amps for 5 sec, and code 35 not active). Check motor, contactor contacts, wiring. |
| 32 | 2,5 | Scrub Deck Lift Actuator Circuit Open | Controller trying to move actuator but sensed no current flow (Senses <= 100 mAmps for 5 sec). Check actuator, wiring. |
| 33 | 3,1 | Vacuum Motor Circuit Open | Controller energized vacuum contactor but sensed no current flow through ground circuit (Senses <= 3 Amps for 5 sec, and code 36 not active). Check motor, wiring. |
| 35 | 3,2 | Brush Contactor Coil Circuit Open | Controller attempted to energize brush contactor but sensed no current flow (Senses <= 20 mAmps for 5 sec). Check for open contactor winding, wiring. |
| 36 | 3,3 | Vacuum Contactor Coil Circuit Open | Controller attempted to energize vacuum contactor but sensed no current flow (Senses <= 20 mAmps for 5 sec). Check for open contactor winding, wiring. |
| 37 | (N/A) | Detergent Pump Circuit Open | Controller energized pump but sensed no current flow (Senses <= 30 mAmps for 5 sec). Check for open pump winding, wiring. |
| 38 | (N/A) | Brush Remove Contactor Coil Circuit Open | Controller attempted to energize brush remove contactor but sensed no current flow (Senses <= 20 mAmps for 5 sec). Check for open contactor winding, wiring. |
| 60 | 3,4 | Brush Motor Contactor Stuck Closed | Controller sensing current flow through brush motor ground circuit when not energized (Senses >= 4 Amps for 5 sec, and code 63 not active). Check for "welded" contacts. |
| 61 | 3,5 | Vacuum Motor Contactor Stuck Closed | Controller sensing current flow through vacuum motor ground circuit when not energized (Senses >= 3 Amps for 5 sec, and codes 64/65 not active). Check for "welded" contacts. |
| 62 | 4,1 | Solution Solenoid Circuit Stuck On | Controller sensing current flow through internal switch for solution solenoid when not requested (Senses >= 20 mAmps for 5 sec). |
| 63 | 4,2 | Brush Contactor Coil Circuit Stuck On | Controller sensing current flow through internal switch for brush contactor when not requested (Senses >= 20 mAmps for 5 sec). |
| 64 | 4,3 | Vacuum Contactor Coil Circuit Stuck On | Controller sensing current flow through internal switch for vacuum contactor when not requested (Senses >= 20 mAmps for 5 sec). |
| 65 | (N/A) | Brush Remove Contactor Coil Circuit Stuck On | Controller sensing current flow through internal switch for brush remove contactor when not requested (Senses >= 20 mAmps for 5 sec). |
| 70 | 4,4 | Corrupt Communication From On-Board Battery Charger | Battery Charger did not properly repeat charging profile message to Main Machine Controller. |
Service Test Mode
This mode allows technicians to test outputs (like brush motors) and verify inputs by bypassing normal operating conditions. The procedure differs for ST (rocker switches) and Non-ST (membrane switches) models.
- ST Models: Enter by holding all three switches (Vacuum, Scrub, Solution) in the UP position while turning the key ON. The low solution flow indicator light remains ON to confirm entry.
- Non-ST Models: Enter by pressing and holding the scrub ON/OFF and Vacuum/Wand switches together while turning the key ON. Release switches when display shows "Programming Options". Navigate to "SERVICE TEST MODE" using Solution Decrease, then press Solution ON/OFF to enter.
Output Tests: Include Brush Deck Lift Actuator, Solution Solenoid, Brush Motor Contactor, Vacuum Motor Relay, Detergent Pump (Non-ST), Brush Remove Contactor (Non-ST). Tests involve operating switches and observing actuator movement, listening for clicks, or checking indicator lights/LCD displays.
Input Tests: Verify inputs like Speed Control Forward/Reverse Signal (ST models use Battery LEDs) and Battery Voltage (Non-ST models display on LCD).
Programming Options
These options configure the Main Machine Controller to match the specific machine equipment and user preferences. They are accessed via a "hidden menu" on the LCD for Non-ST models or specific switch combinations for ST models.
Mandatory Program Options
- Scrub Deck Type: Configures settings for 28 Inch Cylindrical, 26 Inch Disc, or 34 Inch Disc brushes.
- Battery Charger Selection: Selects between no on-board charger, or specific profiles for SPE or Delta-Q chargers with different battery types (Wet, AGM, Gel).
Additional Program Options
- Low Voltage Cut Out Selection: Sets voltage thresholds to protect batteries.
- Lock Out Brush Pressure: Disables Low or High pressure settings.
- Lock Out Solution Flow Rate: Disables specific solution flow rate selections.
- Recovery Tank Full Enable/Disable: Controls automatic shutoff feature.
- Restore Factory Defaults: Resets all settings.
- Fault Recall: Checks and clears historical fault codes.
- Fault Detection: Enables or disables fault detection checks.
- Software Revision Code: Displays the software version.
(Note: Detailed programming procedures and specific values for ST and Non-ST models are provided in the original document.)
Removal and Installation - Main Machine Controller
Detailed procedures are provided for replacing the Main Machine Controller on early and later builds of both ST and Non-ST models. These procedures include steps for accessing the controller, disconnecting wiring, and reassembling. ESD precautions are emphasized. After installation, mandatory program options must be set.
Specifications - Shop Measurements Main Machine Controller
Tables provide typical voltage measurements for various pins on the J1, J2, and J3 connectors of the Main Machine Controller, aiding in diagnosis.
J1 Connector
| Pin # | Circuit Description | Value | Comments | Used on |
|---|---|---|---|---|
| 1 | Chemical Pump "+" output | 24v down | With red lead at pin #4 and black lead at pin #5 | Non ST |
| 2 | Not used | Both | ||
| 3 | Chemical Pump "-" output | -24v up | Both | |
| 4 | Brush Head Actuator motor "+" output | 0.5mV | With vacuum motor running | Non ST |
| 5 | Brush Head Actuator motor "-" output | Both | ||
| 6 | Not used | Both | ||
| 7 | Not used | Both | ||
| 8 | Battery Negative (Ground) | 0.5mV | With vacuum motor running | Both |
| 9 | Not used | Both | ||
| 10 | Not used | Both |
J2 Connector
| Pin # | Circuit Description | Value | Comments | Used on |
|---|---|---|---|---|
| 1 | Battery Negative (Ground) | 0.5mV | With vacuum motor running | Both |
| 2 | Battery Negative (Ground) | 0.5mV | With vacuum motor running | Both |
| 3 | Input from Brush Deck actuator position switch #0. Switch floats open when actuator is fully retracted (corresponding to a raised deck), and is closed to GND otherwise. | 4.95V | Up Position. Other positions 0.5mV | Both |
| 4 | Not used | Both | ||
| 5 | Not used | Both | ||
| 6 | Not used | Both | ||
| 7 | Battery Negative (Ground) | 0.5mV | With vacuum motor running | Both |
| 8 | Battery Negative (Ground) | 0.5mV | With vacuum motor running | Both |
| 9 | Vacuum Motor Current Sense input (voltage on this wire represents the motor current) | 181 mV | Vacuum motor running with solution cover open. Dropped to 157 mV when ball float was seated. | Both |
| 10 | Brush Motor Current Sense input (voltage on this wire represents the motor current) | 30mV | Brushes free running – not contacting floor | Both |
| 11 | Input from Brush Deck actuator position switch #1. Switch floats open when actuator is partially extended (corresponding to normal scrub pressure), and is closed to GND otherwise. | 4.96V | Normal scrub position. Other positions 0.5mV | Both |
| 12 | Pin has 2 functions: 1) Input from Brush Deck actuator position switch #2. Switch floats open when actuator is fully extended (corresponding to maximum scrub pressure), and is closed to GND otherwise. 2) When an S.P.E. on-board battery charger is installed and plugged into an AC outlet, the input function of this signal is overridden and instead becomes a 1-wire, bidirectional serial communication line between the PC board and the on-board charger. | 2.91V | Extra scrub pressure position. Other positions 795mV. If the S.P.E. Battery Charger is plugged in, voltage pulses then settles in around 12V | Both |
J3 Connector
| Pin # | Circuit Description | Value | Comments | Used on |
|---|---|---|---|---|
| 1 | Battery "+" lead | 24.0v | With vacuum motor running | Both |
| 2 | Battery "-" lead | 0.5mV | With vacuum motor running | Both |
| 3 | Brush Remove contactor output | 28mV | When energized. Otherwise 24V | Non ST |
| 4 | On-Board Charger Interlock input (input = key switch voltage when on-board battery charger is not plugged into AC outlet, floats open when on-board charger is plugged in.) | 25V | Key on and Charger NOT plugged in. When Charger is plugged in, drops to 116mV | Both |
| 5 | Reverse Direction input from Speed Controller (input = GND when moving in reverse) | 2mV | In Reverse. | Both |
| 6 | Fwd/Reverse input from Speed Controller (input = GND when moving in forward or reverse) | 23V | In Neutral. | Both |
| 7 | Speed Controller Status input (input pulses between B+ and GND to indicate error status from Speed Controller) | 121mV | Normal (No faults). Voltage pulses when fault is present. | Both |
| 8 | Battery "+" lead | 24.0v | With vacuum motor running | Both |
| 9 | Not used | Both | ||
| 10 | Not used | Both | ||
| 11 | Solution Solenoid Valve winding | 116mV | When energized (Hold solution button down) | Both |
| 12 | Vacuum Contactor winding | 4.9V | When energized, voltage initially drops to 90mV then settles at 4.9v. This is due to 100% "on" time at first to pull in the contactor, which is then reduced to 80% to hold it in. | Both |
| 13 | Brush Motor Contactor winding | 4.9V | When energized, voltage initially drops to 90mV then settles at 4.9v. This is due to 100% "on" time at first to pull in the contactor, which is then reduced to 80% to hold it in. | Both |
| 14 | Key Switch input (input = B+ voltage when key is turned on) | 24.9V | Key On or Off with on-board battery charger | Both |
Electrical System
Functional Description - General
The electrical system is powered by four 6-volt batteries, totaling 24 volts. Heavy cables connect the batteries in series. A Main Battery Pack Connector provides power. On machines without an on-board charger, this connector is used for external charging. The control system reduces power to scrub and recovery systems as battery voltage drops to prevent excessive discharge. A steel plate at the back of the solution tank serves as the electrical panel, mounting relays, fuses, and the Drive Motor Controller. Circuit breakers and a main fuse protect circuits. Wiring is color-coded and identified with wire numbers (e.g., "J1-4 X1-1") for tracing.
On-board Battery Charger
An optional on-board battery charger is available, either an S.P.E. (early) or a Delta-Q IC650 (later). Both have an internal relay that interrupts power when the charger is plugged into AC power (Interlock circuit), preventing operation during charging.
S.P.E. Battery Charger Details
Non-ST models: Display charging profile text and progress icons on LCD. ST models: Communicate charging progress via Battery Indicator LEDs, and charging profile via other control panel LEDs.
Communication between the S.P.E. charger and Main Machine Controller occurs via a WHT/BLU wire. The charger contacts the controller to determine battery type for the correct charging profile. If communication fails, a default profile (wet battery, 25 Amp rate) is used. Refer to Control System, Program Options for battery type settings.
Delta-Q IC650 Battery Charger Details
This charger is a stand-alone unit and does not communicate with the main machine controller. It has a separate LED for charging progress. The correct charging profile must be selected to match the installed batteries. Refer to the Delta-Q Product Manual for profile selection instructions.
Delta-Q IC650 Battery Charging Profile Table
| Battery Manufacturer | Voltage | Battery Model # | 20 Hour Rating | N-A P/N | Profile to use |
|---|---|---|---|---|---|
| DISCOVER | 6 | EV250A-AGM | 260 | 40953A | P-0-4-3 |
| DISCOVER | 6 | EV305A-A | 312 | 56112546 | P-0-4-3 |
| DISCOVER | 6 | EV305A-A | 312 | 56112546 | P-0-4-3 |
| DISCOVER | 6 | EV305A-AGM | 312 | 56315959 | P-0-4-3 |
| DISCOVER | 6 | EVGT6A | 255 | 40964A | P-0-4-3 |
| DISCOVER | 6 | EVGT6A | 255 | 56112545 | P-0-4-3 |
| DISCOVER | 6 | EVL 16A-A | 390 | 56315772 | P-0-4-3 |
| DISCOVER | 12 | EV12A-A | 140 | 56388582 | P-0-4-2 |
| DISCOVER | 12 | EV185A- A | 234 | 56380239 | P-0-4-3 |
| DISCOVER | 12 | EV185A-A | 234 | 56393912 | P-0-4-3 |
| EAST PENN MFG. CO. | 6 | 8GGC 2/T881 (GEL CELL) | 180 | 41023A | P-0-2-6 |
| EAST PENN MFG. CO. | 12 | 8G27MM/T876 | 86.4 | 56206987 | P-0-2-6 |
| FULL RIVER | 6 | DC 250-6 | 250 | 56206988 | P-1-5-1 |
| FULL RIVER | 6 | DC 335-6 | 335 | 56112545 | P-1-4-1 |
| TROJAN | 6 | J -305G | 285 | 56112546 | P-0-0-7 |
| TROJAN | 6 | J-250-2992-41 | 250 | 56391391 | P-0-0-3 |
| TROJAN | 6 | L16-5592-41 | 395 | NOT RECOMMENDED | P-0-0-3 |
| TROJAN | 6 | T-125LPT | 235 | 56026200 | P-0-0-3 |
| TROJAN | 6 | T-605LPT | 195 | 56388582 | P-0-0-3 |
| TROJAN | 12 | J185-2292-42 | 195 | 56206079 | P-0-7-3 |
| US BATTERY | 6 | L16 | 375 | 56206117 | P-0-7-3 |
| US BATTERY | 6 | L16 | 415 | 56206078 | P-0-7-3 |
| US BATTERY | 6 | L16HC | 235 | 40602A | P-0-1-1 |
| US BATTERY | 6 | US-125 | 235 | 40704A | P-0-1-1 |
| US BATTERY | 6 | US-125 | 235 | 56206079 | P-0-1-1 |
| US BATTERY | 6 | US-125 | 235 | 40136A | P-0-1-1 |
| US BATTERY | 6 | US-125 | 235 | 40136B | P-0-1-1 |
| US BATTERY | 6 | US-14 | 251 | 56317154 | P-0-7-2 |
| US BATTERY | 6 | 5XC | 201 | 56206117 | P-0-1-1 |
| US BATTERY | 6 | US1800 | 275 | 56026200 | P-0-1-1 |
| US BATTERY | 6 | US250HC | 305 | 891384 | P-0-7-2 |
| US BATTERY | 6 | US-305 | 305 | 891385 | P-0-7-2 |
| US BATTERY | 6 | US-305 | 305 | 56391391 | P-0-7-2 |
| US BATTERY | 12 | UB27 | 86 | 40070A | P-0-0-6 |
| US BATTERY | 12 | US-185 | 195 | 871334 | P-0-1-1 |
| US BATTERY | 12 | US-185 | 195 | 871335 | P-0-1-1 |
| US BATTERY | 12 | US-185 | 195 | 56206078 | P-0-1-1 |
| US BATTERY | 12 | US-31TMX | 130 | 40605A | P-0-7-1 |
| US BATTERY | 12 | US-31TMX | 130 | 40606A | P-0-7-1 |
Component Locations
Key electrical system components include Batteries, Main Battery Pack Connector, Battery Charger (Optional), Electrical Panel, Main Fuse, Battery Negative Stand Off, and Circuit Breakers.
Electrical Panel Components
The electrical panel houses components such as the 150 Amp Fuse F1, Brush Remove Relay K3, Vacuum Relay K1, Drive Motor Controller A2, Brush Contactor K2.
Maintenance and Adjustments
Battery Maintenance and Recharging
Refer to the Instructions for Use Manual for detailed battery maintenance and recharging procedures.
Troubleshooting
Insufficient Machine Operation Time
Possible causes include incorrect low-voltage cutout setting, batteries not fully charged (recommend 16 hours charging if in doubt), weak batteries (check individual battery voltages or use a load tester/hydrometer), or battery cable connection issues.
The Battery Charger Does Not Charge
Possible causes include a defective Battery Charger, wiring/connection issues, or defective Batteries. Note that the S.P.E. on-board charger may still charge even if it cannot communicate with the Main Machine Controller.
Removal and Installation
Batteries
WARNING!
Exercise extreme caution with batteries. Sulfuric acid can cause severe injury. Explosive hydrogen gas is vented; keep away from sparks or flames. Do not install lead-acid batteries in sealed containers. Always disconnect the negative (ground) cable first when replacing batteries to prevent sparks. Always connect the negative cable last when installing batteries. Wear safety glasses, rubber gloves, and a rubber apron. Work in a well-ventilated area. Do not allow tools to bridge terminals.
CAUTION!
Improper battery installation can severely damage electrical components. Only Nilfisk-Advance, a qualified electrician, or the battery manufacturer should install batteries.
Procedure: Empty recovery tank and tip it up. Turn key OFF and disconnect main battery pack connector. Remove battery cables (preventing tools from bridging terminals). Remove battery. Install new battery. Reconnect battery cables according to the diagram molded into the lower side of the recovery tank.
Battery Charger - S.P.E.
The charger is mounted to the bottom of the frame with 4 bolts. Procedure: Drain tanks, remove batteries, lay machine on its side. Cut tie straps securing AC power cable and electrical connectors. Disconnect connectors. Remove mounting bolts. Remove charger, threading AC power cable through opening. Reassemble in reverse order, using new tie straps.
Battery Charger - Delta-Q
Procedure: Drain tanks, remove batteries, lay machine on its side. Cut tie straps securing AC power cable and electrical connectors. Remove DC connector cover (B). Remove clamp (C). Disconnect battery positive/negative wires (6) and interlock wire (7). Disconnect AC power cable (E) and battery temperature sensor connector (D). Remove 4 mounting bolts. Remove charger. Reassemble in reverse order, using new tie straps.
Specifications
Low Voltage Cut Out Threshold Voltages
The Main Machine Controller shuts down functions in two stages to preserve battery life:
| Stage | Threshold (volts) Wet Batteries | Threshold (volts) Gel Batteries | Shuts Down |
|---|---|---|---|
| 1 | ≥ 20.55 V | ≥ 21.75 V | Brushes, solution, detergent, and raises brush deck. |
| 2 | ≥ 20.40 V | ≥ 21.60 V | Vacuum. |
Battery Run Time
Typical run times are approximately 2-4 hours.
Battery Compartment Dimensions
Length = 24.5" (62.23 cm), Width = 14.25" (36.2 cm), Height = 14.25" (36.2 cm).
Wiring Diagrams
The manual includes several detailed wiring diagrams and harness configuration diagrams for various models and revisions:
- Wiring Diagram - Non-ST, 56112170 Rev D, Early (before SN 4000077687)
- Wiring Diagram - Non-ST, 56383889 Rev E, Late (Since SN 4000077687)
- Wiring Diagram - ST, 56112180 REV C, Early (before SN 4000077687)
- Wiring Diagram - ST, 56383366 REV E, Late (since SN 4000077687)
- Wiring Harness Configuration Diagram - Non-ST, 56112171 REV D, Early (before SN 4000077687)
- Wiring Harness Configuration Diagram - Non-ST, 56383890 Rev A, Late (since SN 4000077687)
- Wiring Harness Configuration Diagram - ST, 56112181 REV C, Early (before SN 4000077687)
- Wiring Harness Configuration Diagram - ST, 56383367 REV B, Late (since SN 4000077687)
- TrackClean Connections, With Access Control 56384628 Rev A
- TrackClean Electrical Connections, Without Access Control 56384627 Rev A
These diagrams illustrate the electrical connections and routing for various machine systems and optional accessories.
Options and Accessories
- Battery Fill Indicator: Provides a visual LED indication when a battery cell is low on water.
- Battery Watering Kit: A system for conveniently adding water to all battery cells simultaneously via manifolds and hoses.
- Hour Meter: Tracks the run time of the scrub motors.
- On-board Battery Charger: Optional charger (SPE or Delta-Q) that mounts to the machine. Wiring modifications may be required for the interlock circuit.
- Parking Brake: Optional kit with a manual lever to press a plunger against a drive wheel for braking.
- Laser: Provides a visual cue for cleaning path width and an early warning of approaching machines.
- TrackClean: An add-on option for machine location and operation data, potentially including a magnetic key reader for operation control.
Recovery System
Functional Description
The recovery system collects dirty water from the floor and stores it in the recovery tank. Airflow created by a vacuum motor lifts water into the tank via the squeegee tool. Wastewater and air enter at the squeegee, travel through the hose to the tank where water settles. Air passes through the vacuum motor. A debris tray catches large particles. A floating ball float seals the vacuum port when the tank is full, shutting off the vacuum motor. The squeegee is raised/lowered manually. The vacuum motor circuit involves a relay controlled by the Main Machine Controller, which also monitors motor current draw via a sense wire.
Component Locations
Key components include: Recovery Tank, Vacuum Motor Cover, Recovery Tank Lid, Vacuum Motor, Gasket, Recovery Lid, Vacuum Relay (Contactor) K1, Recovery Tank Drain Hose, Debris Tray, Squeegee Vacuum Hose, and Cage and Ball Float.
Troubleshooting
Vacuum Motor Does Not Turn On (Scrub function works)
Possible causes: Defective Vacuum Motor, Defective Vacuum Motor Contactor (Relay) K1, Defective Wiring, or a defective Main Machine Controller.
Insufficient Water Pickup
This depends on proper airflow through the squeegee. Restricted airflow or air leaks reduce pickup. Possible causes include: Clogged/kinked squeegee vacuum hose; clogged vacuum motor inlet/outlet; damaged squeegees; air leaks (recovery tank lid gasket, cracked hose, cracked recovery tank). Testing involves a visual inspection and potentially a vacuum gauge (PN 56205281) to measure vacuum at the hose end and with an adapter.
Removal and Installation
Vacuum Motor
Procedure: Turn key OFF, drain recovery tank, lift tank. Cut tie straps securing wiring and disconnect motor connector. Remove vacuum motor cover screws and cover. Remove vacuum motor and foam pieces, noting foam positioning. Reassemble in reverse order, ensuring foam pieces are correctly positioned and motor ends are seated properly. Gravity can be assisted by placing the machine upside down.
Specifications
- Vacuum Motor: 0.66 HP (490 watt) three-stage.
- Vacuum Performance: Blocked off (at squeegee hose end) - 51.2" H20 minimum. With 1 inch hole - 8.7" H20 minimum.
- Vacuum Motor Amp Draw: 17 Amps (with everything assembled, squeegee off floor).
Special Tools
- Water Lift Gauge, part number 56205281
- 1 inch open hole adaptor (can be fabricated from PVC pipe)
Scrub System Cylindrical
Functional Description
The cylindrical scrub system moves the scrub head and spins brush motors upon operator request. Brushes spin towards each other. An electric actuator motor with integrated position switches moves the head up/down. Scrubbing pressure is primarily from the head's weight, with a spring assisting. Cylindrical decks do not have an 'extreme pressure' mode. The Main Machine Controller energizes brush motors via a contactor when the key is ON, the operator requests it, and the machine is moving. The controller monitors brush motor current and actuator position switches.
Component Locations
Components include: Brush Head, Debris Hopper, Idler Assembly, Brush Drive Belt, Brush Head Actuator, Brush Contactor, and Brush Drive Motor.
Troubleshooting
Scrub Motors Do Not Turn On
Possible causes: Brush Contactor issues (winding, contacts), Wiring, Main Machine Controller (not energizing contactor), or Drive Motor Controller (not providing machine moving signal).
Brush Head Will Not Raise or Lower
Possible causes: Mechanical binding of actuator linkage, Brush Head Actuator (motor or position switches), Wiring, or Main Machine Controller. Testing involves checking the actuator motor and its position switches using an ohmmeter and applying power directly. Specific switch continuity checks are detailed.
Removal and Installation
Procedures are provided for removing and installing the Scrub Brush, Brush Drive Belt, Brush Head Actuator, Brush Motor, and Motor Carbon Brushes. These involve disconnecting power, removing covers, belts, and fasteners, and carefully handling components.
Specifications
- Scrub Motor Total Amp Draw: 45-65 Amps (both motors) when scrubbing with low solution flow.
- Scrub Motor Speed: 830-840 RPM.
- Scrub Force: 80 lbs. (36.3 kg).
- Brush Head Actuator Amp Draw: Approx. 1-2 Amps (upward with deck weight).
- Brush Contactor Winding Resistance: 55 ohms.
Scrub System Disc
Functional Description
The disc scrub system functions similarly to the cylindrical system but includes an 'Extreme Pressure' mode. This mode is achieved by the actuator moving the deck further down, engaging a gas spring for additional downward pressure. It has three actuator position switches: retracted, middle (normal pressure), and extended (extreme pressure). The brush disc remove feature is also described, which uses a sequence of motor starts and stops to release brushes.
Component Locations
Components include: Brush Head (Deck), Brush Plate, Brush Motor, Gas Spring, Brush Head Actuator, Brush Contactor, and Brush Remove Relay.
Troubleshooting
Scrub Motors Do Not Turn On
Possible causes: Brush contactor issues, Wiring, Main Machine Controller, or Drive Motor Controller.
Scrub Deck Will Not Raise or Lower
Possible causes: Mechanical binding, Brush Head Actuator (motor or position switches), Wiring, or Main Machine Controller. Detailed testing procedures for actuator motor and position switches are provided, similar to cylindrical systems but accounting for the 'extended' position switch.
Removal and Installation
Procedures cover Brush Head, Brush Motor, Drive Motor (including bearing and eccentric), Motor Plate and Isolators, Scrub Motor Carbon Brushes, and Brush Head Actuator. These involve disassembly and reassembly steps with specific torque values and Loctite recommendations.
Specifications
- Scrub Motor Amp Draw (No Load): Approx. 4 Amps (one motor).
- Scrub Motor Total Amp Draw: 12-32 Amps (both motors) in normal scrub mode; 30-45 Amps in extreme scrub mode.
- Scrub Motor Speed: Approx. 2,000 RPM.
- Scrub Force: Regular Scrub = 70.4 lbs. (31.9 kg); Extreme Scrub = 170 lbs. (77.1 kg).
- Brush Head Actuator Amp Draw: Approx. 2 Amps (upward with deck weight).
- Brush Contactor Winding Resistance: 55 ohms.
- Gas Spring Force: 112 pounds (500 N).
Solution System
Functional Description
The solution system dispenses water and detergent to the scrub brush head. It includes a solution tank, shut-off valve, filter, solenoid valve, and manifold. Disc decks deliver solution near the center; cylindrical decks deliver it via hoses along the front. The filter protects the solenoid valve. The tank level is sensed via a pressure sensor connected to a sealed hose. Standard systems require manual mixing of detergent; optional detergent mixing systems automatically blend water and detergent using a piston pump and controller. The solenoid valve controls flow rate by cycling on/off. Solution flow stops when the machine stops moving. The detergent system tracks detergent usage based on pump strokes.
Component Locations
Components include: Solution tank, Shut off valve (Ball Valve), Solution filter, Solution solenoid valve, Detergent pump, Detergent tank, and Solution drain hose.
Maintenance and Adjustments
Solution Filter Cleaning
Procedure: Turn key OFF, close shut-off valve, unscrew filter cover, remove and clean screen. Reassemble carefully, avoiding over-tightening the cover. Open shut-off valve.
Troubleshooting
Insufficient Solution Flow
Possible causes: Restricted solution filter, debris in tank clogging fitting, pinched hose, or restricted solution valve.
Solution Leaks After Machine Is Shut Off
Possible causes: Solution valve not sealing (worn or debris), or hose/fitting leak before the solution valve.
Detergent Is Not Being Added to the Solution (Machines with optional detergent mixing system)
Possible causes: Detergent tank empty, blocked/leaking detergent hose, Detergent pump issue, Wiring problem, or Main machine controller issue.
Removal and Installation
Solution Valve
Procedure: Turn key ON, lower brush head, unplug actuator. Turn key OFF, close shut-off valve. Remove mounting plate screws, hose clamps, hoses, and electrical connector. Reassemble in reverse order.
Solution Tank
Procedure: Empty tanks, remove brush head, actuator, recovery tank, and batteries. Remove handle assembly and control panel cover. Disconnect wiring and pressure sensor hose. Remove shut-off valve elbow. Remove tank mounting bolts and separate tank from frame.
Specifications
- Solution valve winding resistance: 54 ohms.
- Solution flow: Maximum = 0.75 gallons/minute.
- Detergent pump winding resistance: 37 ohms.
Squeegee System
Functional Description
The squeegee collects water for the recovery system. The support is spring-loaded downward and pivots to follow corners. The tool rides on small wheels and is raised/lowered by a hand lever. It mounts in slotted holes with wing nuts for breakaway protection. The squeegee angle is adjustable. Blades have four working edges. The front blade has slots for airflow; the rear blade is flat.
Component Locations
Components include: Squeegee Support, Squeegee Tool, Squeegee Lift Lever, Break Away Slots, and Tilt Adjustment Knob.
Maintenance and Adjustments
Adjusting Squeegee Tilt
Procedure: Park on a flat surface, lower squeegee. Move machine forward slowly and turn the Squeegee Tilt Adjustment Knob until the rear blade flares evenly across the width.
Troubleshooting
Leaving Streaks on the Floor
Possible causes: Debris between blade and floor, worn/torn blade edges, incorrect squeegee tilt, broken squeegee springs, or bent squeegee support.
Removal and Installation
Squeegee Tool
Procedure: Remove vacuum hose. Loosen wing nuts. Remove squeegee tool. Reassemble, being careful not to over-tighten wing nuts to preserve the breakaway feature.
Squeegee Support
Procedure: Remove squeegee tool. Disconnect lift cable. Lift support against spring tension and tie it up to neutralize spring force. Remove pivot mounting nut and assembly. Reassemble, cutting the wire used to hold spring tension.
Squeegee Blades
Blades have 4 working edges and can be rotated. Front Blade: Remove tool, loosen tension strap screw, remove strap and blade. Install new blade, matching slots, reinstall strap, tighten screw. Rear Blade: Remove tool, unsnap center latch, remove tension straps and blade. Install new blade, matching slots, reinstall tension straps, close latch.
Wheel System - Non-Traction
Functional Description
A single caster wheel mounted at the rear of the frame allows for easy machine pivoting. It is attached with four bolts.
Component Locations
Component: Caster Wheel.
Wheel System, Traction
Functional Description
A permanent magnet motor transaxle propels the machine forward and reverse. Controls differ between ST (palm drive buttons, reverse button, speed control potentiometer) and Non-ST (drive paddle with angle sensor, speed limit potentiometer) models. The Drive Motor Controller manages speed and direction by varying voltage and polarity. It communicates machine movement and direction to the Main Machine Controller. Speed in reverse is intentionally lower than forward.
Drive Motor Circuit Description - SC750 ST and SC800 ST models
The controller powers up via the key switch (and potentially the charger interlock). Inputs monitored: Palm Switches (for movement request), Speed Request (via potentiometer), and Reverse Switch (for direction). Outputs control the transaxle motor and provide movement/direction signals (FOR/REV, REV) to the Main Machine Controller.
Drive Motor Circuit Description - SC750 and SC800 models
Similar power-up. Inputs: Drive Paddle Position (for movement and direction), Speed Limit Potentiometer. The drive paddle position sensor returns voltage to the controller indicating movement and direction. A stationary paddle position (middle) results in zero voltage, indicating no movement.
Component Locations
Components include: Drive Motor, Transaxle, Wheels, Speed Control Potentiometer, Drive Paddle, Palm Drive Buttons, Reverse Button, etc.
Troubleshooting
Does Not Propel Forward or Reverse with No Trip Type Set
Possible causes include issues with the Drive Motor Controller, wiring, or the drive motor itself.
Reading LED Trip Type Values
This refers to diagnostic codes related to the drive system, typically indicated by LED flashes on the control panel.
Removal and Installation
Procedures are detailed for components such as the Speed Limit Potentiometer, Reverse Switch, Handle Wiring Connections, Paddle Position Sensor, Paddle Centering Springs, Drive Wheel, Transaxle, and Transaxle Drive Motor Carbon Brushes.
Specifications
Specifications for traction wheel systems, including motor details, amp draws, and speeds, are provided in the original document.