Advance SC6500 Service Manual

SC6500 service manual

Form No. 56043168. 01/15, revised 12/17. English.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​​​‌​​​‌​‍‍​‌‍‌⁠⁠​​⁠‍​⁠​⁠‌​​‌⁠‍‍​⁠⁠‍

Advance model numbers:

• 56414010 SC6500 40C
• 56414011 SC6500 40C ECOFLEX
• 56414012 SC6500 40D
• 56414013 SC6500 40D ECOFLEX
• 56414014 SC6500 45C
• 56414015 SC6500 45C ECOFLEX
• 56414016 SC6500 45D
• 56414017 SC6500 45D ECOFLEX
• 56414018 SC6500 48C
• 56414019 SC6500 48C ECOFLEX
• 56414020 SC6500 48D
• 56414021 SC6500 48D ECOFLEX

Nilfisk model numbers:

• 56414022 SC6500 1100D
• 56414023 SC6500 1100C
• 56414024 SC6500 1300D
• 56414025 SC6500 1300C
• 56414026 SC6500 1100D ECOFLEX

Contents

General Information

• General Machine Description (p. 9)
• Service Manual Purpose and Application (p. 9)
  • Conventions (p. 9)
  • Feedback (p. 9)
• Revision History (p. 9)
• Other Manuals and Information Sources (p. 9)
  • Electronic Databases (p. 9)
  • Manuals (p. 9)
• Parts and Service (p. 10)
• Nameplate (p. 10)
• Transporting the Machine (p. 10)
• Towing (p. 11)
• Caution and Warning Symbols (p. 11)
• General Safety Instructions (p. 11)
• Emergency-stop Switch/Battery Disconnect (p. 13)
• Technical Specifications (As Installed and Tested On The Unit) (p. 14)
  • Advance Brand SC6500 Models (p. 14)
  • Nilfisk Brand SC6500 Models (p. 16)
• Dimensions (p. 18)
• General Machine Overview (p. 19)
  • Major Machine Components (p. 19)
  • Control Panel (p. 21)
    • Switch and Button Functions (p. 21)
    • Control Panel Indicators (p. 24)
    • Control Panel Display (p. 26)
    • Caution Displays (p. 26)
    • Circuit Breakers (p. 27)
• General Maintenance (p. 27)
  • Maintenance After Use (p. 27)
  • Maintenance Schedule (p. 28)
  • Machine Lubrication (p. 29)
  • Lubrication Points (p. 29)
• PM Check List - SC6500 (p. 30)

Chassis System

• Major Chassis Components (p. 32)

Control System

• Functional Description (p. 33)
  • Overview (p. 33)
    • A2 Control Board Assembly (p. 33)
    • A3 Switch/Display Panel Assembly (p. 34)
  • Circuit Description (p. 34)
• Main Control Programming Options (p. 34)
  • Fault Recall Mode (p. 34)
  • To Select the Battery Used in the Machine (p. 35)
  • To Restore the Scrub Pressures to the Factory Default Settings (p. 35)
  • To Enable/Disable the Fault Detection (p. 35)
  • To Display the Control Board Revision Level (p. 36)
  • Monitor Mode (p. 36)
  • Scrub Deck Down Time Adjustment (p. 36)
  • Normal (Light) Scrub Setting Adjustment (p. 37)

Contents (continued)

• • Heavy Scrub Setting Adjustment (p. 38)
  • Extreme Scrub Setting Adjustment (p. 38)
  • Scrub Speed Switch Lockout (p. 39)
  • Detergent System Selection Mode (p. 40)
  • EcoFlex™ Mode Selection (p. 40)
  • Vacuum Motor Configuration Option (p. 40)
  • Recovery Tank Full Detection Enable/Disable (p. 41)
  • Solution Flow in Reverse Enable/Disable (p. 41)
  • Indicator LED Intensity Selection Option (p. 42)
  • Detergent and Solution Pump Purge (p. 42)
    • Method 1 (p. 42)
    • Method 2 (as described in the Instructions for Use) (p. 42)
  • Side Broom Function (p. 43)
  • Side Broom Height Adjustment (p. 43)
  • Display Mode Selection (p. 44)
• Service Test Mode (p. 44)
  • To Enter the Service Test Mode (p. 44)
  • Service Test Mode Display (p. 44)
  • Control Panel Switch and Button Functions (p. 45)
• Troubleshooting (p. 46)
  • Error Indicator and Error Code Display (p. 46)
  • Error Codes (p. 47)
• Removal and Installation (p. 53)
  • A2 Control Board Assembly (p. 53)
• Specifications (p. 54)
• I/O Table with Shop Measurements (p. 55)
  • A2 Control Board Assembly (p. 55)

Electrical System

• Functional Description (p. 59)
  • Overview (p. 59)
  • Low-voltage Cut-out Feature (p. 59)
  • Battery Condition Indicator (p. 59)
• Component Locations (p. 61)
  • Battery Location (p. 63)
• Connector Pin-Outs (p. 64)
• Maintenance and Adjustments (p. 74)
  • Wet-cell Battery Maintenance (p. 74)
  • Checking the Battery Water Level (p. 74)
  • Charging Wet-cell Batteries (p. 74)
    • To Charge the Batteries (p. 75)
    • When Servicing Batteries (p. 75)
  • Troubleshooting (p. 76)
  • Battery Testing (p. 76)
  • General Troubleshooting (p. 76)
• Removal and Installation (p. 77)
  • To Install the Batteries (p. 77)
• Specifications (p. 79)
• Special Tools (p. 79)
• Wiring Diagram Tips (p. 80)
• Wiring Diagram PN 56414095 REV C Sheet 1 of 3 (p. 82)
• Wiring Diagram PN 56414095 REV C Sheet 2 of 3 (p. 83)
• Wiring Diagram PN 56414095 REV C Sheet 3 of 3 (p. 84)
• Wiring Harness Diagram 56414096_REV_C (p. 85)

Options and Accessories

Contents (continued)

Recovery System

• Functional Description (p. 90)
  • Overview (p. 90)
  • Recovery Tank (p. 90)
  • Vacuum Motor (p. 90)
  • Squeegee and Squeegee Hose (p. 90)
  • Float Cage and Ball (p. 91)
  • Recovery System Wiring Diagram (p. 91)
  • Circuit Description (p. 92)
• Component Locations (p. 92)
  • Vacuum Motor and Vacuum Hose (p. 92)
  • Top Cover Assembly (p. 93)
  • Float Cage and Ball (p. 93)
  • Recovery Tank Lid (p. 94)
  • Squeegee and Drain Hoses (p. 94)
• Maintenance (p. 95)
  • To Inspect and Clean the Vacuum Filter and Inlet Screen (p. 95)
  • To Inspect and Clean the Vacuum Motor Float Cage (p. 95)
• Troubleshooting (p. 96)
  • Insufficient Water Pick-up (p. 97)
    • Possible Causes: (p. 97)
    • Troubleshooting Steps (p. 97)
• Removal and Installation (p. 99)
  • Recovery Tank (p. 99)
  • Vacuum Motor (p. 100)
• Specifications (p. 102)
  • Shop Measurements (p. 102)
    • K1 Vacuum Contactor (p. 102)
    • Vacuum Motor (p. 102)
• Special Tools (p. 102)

Scrub System, Cylindrical

• Functional Description (p. 103)
  • Overview (p. 103)
  • Cylindrical Scrub System Wiring Diagram (p. 103)
  • Circuit Description (p. 104)
• Component Locations (p. 105)
• Maintenance and Adjustments (p. 106)
  • General Scrub System Maintenance (p. 106)
    • Daily Maintenance (p. 106)
    • Weekly Maintenance (p. 106)
    • Monthly Maintenance (p. 106)
  • Scrub Brush Belt Replacement (p. 106)
  • Lift Actuator Adjustment (p. 108)
    • Using the Actuator Power Cord Adapter (p. 108)
    • Lift Actuator Drive Nut Adjustment (p. 109)
  • Side Skirt Replacement and Adjustment (p. 113)
• Troubleshooting (p. 114)
• Removal and Installation (p. 116)
  • Scrub Brushes (p. 116)
  • Scrub Brush Deck (p. 117)
  • Scrub Deck Lift Actuator (p. 119)
  • Scrub Brush Motor (p. 120)
• Specifications (p. 121)
  • Shop Measurements (p. 121)
    • Brush Contactor (K2, K3 or K4) (p. 121)
    • Scrub Brush Motor (p. 121)

Contents (continued)

• • • Brush Actuator Motor (p. 122)
• Special Tools (p. 122)

Scrub System, Disc

• Functional Description (p. 123)
  • Overview (p. 123)
  • Disc Scrub System Wiring Diagram (p. 123)
  • Circuit Description (p. 124)
• Component Locations (p. 125)
• Maintenance and Adjustments (p. 126)
  • Lift Actuator Adjustment (p. 126)
    • Using the Actuator Power Cord Adapter (p. 126)
    • Lift Actuator Drive Nut Adjustment (p. 127)
  • Side Skirt Replacement and Adjustment (p. 131)
• Troubleshooting (p. 132)
• Removal and Installation (p. 134)
  • Scrub Brush Deck (p. 134)
  • Scrub Deck Lift Actuator (p. 135)
  • Scrub Brush Motor and Gearbox (p. 136)
    • To Remove and Install a Gearbox Assembly (p. 136)
    • To Disassemble and Reassemble a Gearbox Assembly (p. 136)
• Specifications (p. 137)
  • Shop Measurements (p. 137)
    • Scrub Brush Motor (p. 137)
• Special Tools (p. 138)

Solution System

• Functional Description (p. 139)
  • Overview (p. 139)
  • Solution Tank (p. 140)
  • Shutoff Valve (p. 140)
  • Drain Hose and Hose Cap (p. 140)
  • Solution Filter (p. 140)
  • Solution Control Pump (p. 140)
  • Solution Solenoid Valve (p. 140)
  • Solution Manifold (disc decks only) (p. 140)
  • Accessory Pump (p. 140)
  • Detergent Tank and Pumps (p. 141)
  • Solution System Wiring Diagram (p. 141)
  • Circuit Description (p. 141)
    • Solution System (p. 141)
    • Detergent System (p. 142)
    • Accessory Pump (p. 142)
• Component Locations (p. 143)
  • Shutoff Valve (p. 143)
  • Solution Level Switch (p. 143)
  • Drain Hose and Hose Cap (p. 144)
  • Solution Filter (p. 144)
  • Solution Control Pump (p. 144)
  • Solution Solenoid Valve (p. 145)
  • Solution Manifold (disc decks only) (p. 145)
  • Accessory Pump (p. 145)
  • Detergent Tank and Pumps (p. 146)
• Maintenance and Adjustments (p. 147)
  • To Disassemble and Clean the Solution Solenoid Valve (p. 147)
  • Weekly Maintenance (p. 147)
    • To Empty and Rinse the Solution Tank (p. 147)

Contents (continued)

• • • To Clean the Solution Filter (p. 147)
    • To Clean the Solution Delivery Trough (cylindrical scrub decks only) (p. 148)
    • To Purge the Detergent System (p. 148)
  • To Purge the Detergent System When Changing Detergents (p. 149)
  • To Program the Detergent Ratio (p. 149)
• Troubleshooting (p. 150)
• Removal and Installation (p. 152)
  • Solution Control Pump (p. 152)
  • Solution Solenoid Valve (p. 153)
• Specifications (p. 154)
  • Solution Flow Rates (p. 154)
  • Component Specifications (p. 154)
  • Shop Measurements (p. 154)

Squeegee System

• Functional Description (p. 155)
  • Overview (p. 155)
  • Squeegee System Wiring Diagram (p. 155)
  • Circuit Description (p. 155)
  • Squeegee Lift Actuator Reverse Function (p. 156)
• Component Locations (p. 156)
• Maintenance and Adjustments (p. 157)
  • To Reverse or Replace the Rear Squeegee Wiping Blade (p. 157)
  • To Reverse or Replace the Front Squeegee Blade (p. 157)
  • Squeegee Adjustment (p. 158)
    • To Adjust the Squeegee Angle (p. 158)
    • To Adjust the Squeegee Blade Height (p. 158)
  • Lift Actuator Adjustment (p. 159)
    • Using the Actuator Power Cord Adapter (p. 159)
    • Actuator Drive Nut Adjustment (p. 159)
• Troubleshooting (p. 160)
• Removal and Installation (p. 161)
  • Squeegee Lift Actuator (p. 161)
• Specifications (p. 162)
  • Shop Measurements (p. 162)
    • Squeegee Actuator Motor (p. 162)
• Special Tools (p. 162)

Steering System

• Functional Description (p. 163)
  • • Drive Wheel Steering Assembly (p. 163)
• Maintenance and Adjustments (p. 164)
  • Steering Chain (p. 164)
• Removal and Installation (p. 164)
  • Steering Chain Removal and Tensioning (p. 164)

Sweep System, Side Broom

• Functional Description (p. 166)
  • Overview (p. 166)
  • Side Broom Sweep System Wiring Diagram (p. 166)
  • Circuit Description (p. 167)
• Component Locations (p. 167)
• Maintenance and Adjustments (p. 168)
  • Side Broom Height Adjustment (p. 168)
  • Lift Actuator Adjustment (p. 169)
    • Using the Actuator Power Cord Adapter (p. 169)
    • Lift Actuator Drive Nut Adjustment (p. 169)
• Troubleshooting (p. 171)

Contents (continued)

• Removal and Installation (p. 172)
  • Side Broom Lift Actuator (p. 172)
  • Side Broom Gearmotor (p. 173)
• Specifications (p. 174)
  • Shop Measurements (p. 174)
    • Side Broom Contactor (K6) (p. 174)
    • Side Broom Motor (p. 174)
    • Side Broom Actuator Motor (p. 174)
• Special Tools (p. 175)

Wheel System, Non-traction

• Functional Description (p. 176)
  • Overview (p. 176)
• Component Locations (p. 176)
• Maintenance and Adjustments (p. 177)
  • Brake Cable Adjustment (p. 177)
  • Brake Caliper Pad Wear Adjustment (p. 178)
• Troubleshooting (p. 179)
• Removal and Installation (p. 180)
  • Brake Cable Replacement (p. 180)
  • Rear Wheel and Brake Caliper (p. 181)

Wheel System, Traction

• Functional Description (p. 182)
  • Drive Pedal (p. 182)
  • Wheel Drive Controller (p. 182)
  • Drive Wheel Motor Assembly (p. 182)
  • Wheel Motor, Temp Sensor and Encoder (p. 183)
  • Circuit Description (p. 184)
  • Motor Temperature Sensor (p. 185)
• Component Locations (p. 187)
• Troubleshooting (p. 188)
  • Fault Codes (p. 188)
  • Summary of LED display formats (p. 189)
  • Fault Code Table (Troubleshooting Chart) (p. 190)
  • Troubleshooting Chart (p. 190)
  • Fault History (p. 201)
• Removal and Installation (p. 202)
  • Front Drive Wheel/Tire Removal (p. 202)
  • Front Drive Wheel/Tire Installation (p. 204)
  • Wheel Drive Assembly (p. 205)
    • Potentiometer Testing (p. 207)
    • Drive Pedal Installation (p. 207)
  • Drive Pedal Neutral Adjustment and Pedal Replacement (p. 207)
  • Wheel Drive Controller Replacement (p. 208)
• Specifications (p. 208)
  • General Specifications (p. 208)
  • Speed Mode Table (p. 209)
• Specifications (p. 210)
  • Shop Measurements (p. 210)
    • Wheel Drive Controller Voltage Measurements (p. 210)
    • Low Current 35 Pin Connector (X6) (p. 210)
    • Motor U, V and W Terminal Pair Voltages (p. 211)
    • Motor U, V and W Terminal Pair Frequency (p. 212)
    • Wheel Speed Controller Current Draw (p. 212)
    • Main Contactor (K7) (p. 212)
• Special Tools (p. 213)

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General information

General machine description

The SC6500 machines are battery powered ride-on scrubbing machines. Specific models may be equipped with either cylindrical or disc style scrub decks in several different sizes.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​​‍‌​​​‌​‍‍​​⁠​‍​​⁠​‍‌‌​⁠‍‍⁠​‌‌‌⁠​⁠⁠

Service manual purpose and application

This Service Manual a technical resource designed to aid service personnel in maintaining and repairing the SC6500 scrubber to ensure optimum performance and long service life. Please read it thoroughly before servicing the machine.

Conventions

All references to right, left, front and rear in this manual are as seen from the Operator’s seat position.

Feedback

All comments and suggestions for improving this manual should be emailed to [email protected]. Please include the service manual title, form number, revision date found on the front cover with your communication.

Revision history

Other manuals and information sources

Electronic databases

The manuals listed below can be found on Advance’s electronic supported databases. They are:

• Advance Dealer Customer Zone
• EzParts service / parts CD-ROM
• Nilfisk-Advance website: www.nilfisk-advance.com

Manuals

• Parts List - Form Number 56042608
• Instructions for Use - Form Number 56091095 (English, Spanish. Portugese, French)
• Curtis Programmer Manual Number 56043101

Parts and service

Repairs should be performed by an Authorized Nilfisk-Advance Service Center, which employs factory-trained service personnel and maintains an inventory of Nilfisk-Advance original replacement parts and accessories.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​​‍‍​​​‌​‍‍​‌⁠‍​‌‍‍⁠‍⁠⁠‌⁠‌⁠​​‌‍​​⁠‌‌

Nameplate

The Model Number and Serial Number of your machine are shown on the machine nameplate. This information is needed for selecting the correct technical documentation and when ordering repair parts for the machine.

“Part No” on the label is equivalent to the machine “Model Number”

Note that the Nameplate is attached to the rear of the steering column.

Transporting the machine

Towing

Note: Disconnecting the wheel drive motor wiring connector will make a disabled machine easier to push.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​​‍⁠​​​‌​‍‍​‌⁠‍‌⁠‍​​​⁠‍​⁠‍‌⁠⁠‍⁠‌⁠‌​‌

Caution and warning symbols

Advance uses the symbols below to signal potentially dangerous conditions. Read this information carefully and take the necessary steps to protect personnel and property.

Read all instructions before using.

General safety instructions

Specific Cautions and Warnings are included to warn you of potential danger of machine damage or bodily harm.

Emergency-stop switch/battery disconnect

The Emergency-stop/Battery Disconnect is the red lever located to the right of the Operator’s seat. In the event of an emergency, press the Emergency-stop/Battery Disconnect in (toward the rear of the machine) to disconnect the battery from the machine. This will stop all machine functions.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​​⁠‌​​​‌​‍‍​⁠‌⁠‍​​​​⁠‍‍​​‌‍‌‌⁠‍​‌⁠‍‌

Save These Instructions

Technical specifications (as installed and tested on the unit)

Advance brand SC6500 models

Footnote * is on page 15 and footnote ** on pages 16 and 17.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​​⁠‍​​​‌​‍‍​‍‍‍‌​​​​⁠‍‍‍⁠‌⁠⁠⁠‌‍​⁠‍‍⁠

*Gross Weight: Standard machine without options, full solution tank and empty recovery tank, with removable scrub brushes and batteries installed.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​​⁠⁠​​​‌​‍‍​⁠​⁠‍​​​⁠‍​‍⁠‍​‌‍‌‌⁠‍​‍⁠⁠

**Transportation Weight: Standard machine without options, empty solution and recovery tanks, with batteries installed and no operator.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‌​​​​​‌​‍‍​⁠​​‍‍‌​​⁠⁠‍⁠‌⁠‌⁠‍⁠⁠​⁠‌‍⁠

Nilfisk brand SC6500 models

*Gross Weight: Standard machine without options, full solution tank and empty recovery tank, with removable scrub brushes and batteries installed.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‌​‌​​​‌​‍‍​⁠​‌‍‍‌​‌‌⁠⁠⁠‍⁠‌‍‍‍⁠⁠‌‌​​

**Transportation Weight: Standard machine without options, empty solution and recovery tanks, with batteries installed and no operator.

Dimensions

• Machine length: 73.5 in (187 cm)
• Machine height: 58.5 in (148.6 cm)
• Machine width at rollers and width with squeegee: see the table on page 14.

General machine overview

Major machine components

The label shown at the right of the drawing marks the circuit breakers: F1 3A, F2 15A and F3 20A.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‌​⁠​​​‌​‍‍​​​⁠⁠⁠⁠​⁠⁠‌⁠‍‌⁠⁠‌⁠​​‍⁠‍‍‍

Control panel

Switch and button functions

The controls on your rider scrubber were designed with one-touch operation in mind. For single-pass scrubbing, the user can simply depress one switch and all systems on will be activated. For most single-pass scrubbing operations, the operator should only need to use the middle switches on the control panel. These are the red Scrub Off and the green Scrub On/Pressure Increase Switches.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‌‌‌​​​‌​‍‍​⁠‌​‌‍‍‍​​‌‍​​‌⁠​‍⁠​​‍‌‌​

• Key Switch – main power switch; controls the battery input to the machine’s main control board and the wheel drive speed control.
• Scrub On/Pressure Increase Switch – functions as follows:

  If the scrub system is off, pressing this switch once will put the machine into the Auto Scrub mode. The following will occur:

  • The scrub system will be enabled with the scrub pressure set to the #1 normal setting.

    Note: Press the switch twice for #2 heavy scrub setting, and three times for the #3 extreme scrub setting. Pressing the switch a fourth time will return the system to the normal scrub setting.

  • The scrub deck and squeegee will automatically be lowered. On cylindrical models equipped with side brooms, the side brooms will be lowered.
  • The vacuum system will be enabled.
  • The solution and detergent systems will be enabled. Note that both the solution and detergent flow rates will correspond to the selected scrub pressure mode.
  • As soon as the drive pedal is moved from its neutral position, the scrub brushes and side brooms (if installed) will start turning, and the solution, detergent and vacuum systems will switch on.

• If the direction is forward, the solution and detergent flow will also start automatically.
• If the direction is reverse, the solution and detergent flow will be stopped and the squeegee will be raised just enough to clear the floor surface.

Note: The solution, vacuum and detergent systems are automatically enabled when the Scrub On Switch is pressed to put the machine into the Auto Scrub mode. Any individual system can be toggled off and on by simply pressing the corresponding system switch at any time during scrubbing.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‌‌‍​​​‌​‍‍​⁠‌⁠‍⁠​‌‌‌⁠‍‍‍‌⁠⁠​‌​​⁠⁠‌⁠

If the machine is already scrubbing, pressing the Scrub On/Pressure Increase Switch will increase the scrub pressure to the next higher setting (toggling from regular to heavy, heavy to extreme, then back to normal). The Scrub Pressure Indicator will show the selected scrub pressure (one, two or three bars) in the Control Panel Display.

• Scrub Off Switch – Pressing this switch when the machine is in the scrub mode will cause the following to occur:
  • The scrub brushes will turn off and the scrub deck will be raised to the up position. On cylindrical models equipped with side brooms, the side brooms will shut off and be raised.
  • The solution and detergent flow will be stopped.
  • Once forward machine motion stops, the vacuum/wand switch indicator light will start to blink. After a user-programmable time delay, the squeegee will be raised and the vacuum motors will shut off. Pressing the switch a second time before the vacuum time delay is complete will raise the squeegee and turn off the vacuum motors immediately.
• Solution Switch – functions as follows:
  • If the scrub system is off, pressing and holding this switch will switch on the solution flow to pre-wet the floor. The solution flow will stop when the switch is released. Note this must be done prior to pressing the Scrub On Switch and putting the machine into the Auto Scrub mode.
  • If the machine is in the Auto Scrub mode, pressing this switch will disable the solution system. This is used if you wish to scrub without adding additional solution to the floor.
  • If the machine is in the Auto Scrub mode, you can press and hold the Solution Switch to actuate the solution flow override function. This override function allows you to select a different solution flow rate without changing the scrub pressure. Note that the machine is programmed for two additional higher solution flow rates plus the three normal default flow rates, for a total of five solution flow rates.

    To actuate the solution flow override function, press and hold the Solution Switch for three seconds until the Solution System Indicator flashes, then release it. You’ll have three seconds to select the desired solution flow rate by pressing the Solution Switch. The Solution Flow Indicator will show the selected solution flow rate (one through five bars) in the Control Panel Display. Note that if any scrub pressure change is made while in the solution override mode, the solution flow will return to its default solution flow rate.

• Detergent Switch – functions as follows:
  • If the solution system is enabled, pressing this switch will toggle the detergent system off and on. When the detergent system is on, the detergent pumps will be activated at a specific rate when the drive pedal is actuated. The detergent pump will turn off when the drive pedal is in neutral or reverse.

• If the solution system is off, the detergent pump will not turn on.
• Vacuum/Wand Switch – functions as follows:
  • If the machine is in the Auto Scrub mode, pressing this switch once will raise the squeegee. The vacuum motors will run for a short time delay, then shut off. If you press the switch twice, the vacuum motors will shut off immediately. This is used if you wish to double-scrub (scrub without recovering the solution).
  • If the scrub system is off, the Vacuum/Wand Switch functions differently depending on whether the seat switch is open (no operator in the seat) or closed (operator in the seat).
    • If the operator is in the seat, pressing the switch will lower the squeegee and switch on the vacuum motors. When the machine is moved into reverse, the squeegee will be raised, then lowered when the machine is again moved forward. This mode is used to pickup water from the floor without scrubbing or adding solution.
    • If the operator is not in the seat, pressing the switch will toggle the vacuum motors on and off to allow use of the vacuum wand. In this mode, the squeegee will not move up or down and the recovery tank full indicator is ignored.
• Scrub Speed Switch – When the machine is operating in any one of its scrub settings, the machine’s travel speed is reduced to 80 percent of the maximum transport speed pre-programmed into the speed controller. Pressing the Scrub Speed Switch overrides the 80 percent of transport speed limit and increases the scrub speed to 100 percent of transport speed.
• Traction Control Switch – regulates the drive wheel motor torque to minimize drive wheel slippage in limited traction conditions.
• Side Broom On/Down Switch – lowers and raises the side brooms (only functional on cylindrical models equipped with side brooms). Note that when the scrub system is switched on, the side brooms are lowered to the same position they were in when the scrub system was last turned off (auto memory operating position).

  Note: You can raise or lower the side broom height to maintain the correct broom contact patterns and compensate for normal broom wear. Refer to the Sweep System, Side Broom section for instructions on setting the side broom height.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‌‌⁠​​​‌​‍‍​⁠‌​‍⁠‍‍​​​‍‍​​‍‍⁠⁠⁠‌​‌⁠⁠

• Burst of Power Button – The Burst of Power Button functions differently depending on whether the EcoFlex™ mode is set to Mode 1 or Mode 2. (Also refer to the Control System/Main Programming Options/EcoFlex™ Mode Selection section, page 40.) Note that in Mode 1 the detergent concentration is displayed as a ratio. In Mode 2 the detergent concentration is displayed as a percent.
  • In EcoFlex™ Mode 1, the minimum detergent concentration is displayed as a ratio. Pressing the Burst of Power Button in Mode 1 will do the following:
    • The detergent ratio will change to the maximum concentration programmed ratio. (Also refer to the Solution System/Maintenance and Adjustments/To Program the Detergent Ratio section.)
    • The scrub pressure will increase to the next highest pressure.
    • The solution flow rate will increase to the next highest level.

    After 60 seconds, or after you press the Burst of Power Button again, the detergent ratio will revert to the minimum concentration ratio, and the scrub pressure and solution rate will return to their previous settings.

• In EcoFlex™ Mode 2, the minimum detergent concentration is displayed as a percent.. Pressing the Burst of Power Button in Mode 2 will do the following:
  • The detergent ratio will change to the maximum concentration programmed percentage. (Also refer to the Solution System/Maintenance and Adjustments/To Program the Detergent Ratio section.)
  • The scrub pressure will increase to the next highest pressure.
  • The solution flow rate will increase to the next highest level.

  After 60 seconds, or after you press the EcoFlex™ Button again, the detergent ratio will revert to the programmed ratio, and the scrub pressure and solution rate will return to their previous settings.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‌‍​​​​‌​‍‍​‌⁠​‌‌‍⁠​​‍‌⁠​⁠‍​​‍‍⁠‌⁠⁠⁠

• Horn Button – sounds the horn when pressed.
• Control Panel Display – displays the various icons that indicate scrub pressure, solution flow rate, detergent ratio, battery charge state and a recovery tank full condition. The display also shows any error conditions detected by the main control board.

Control panel indicators

In general the following guidelines apply to the control panel indicators:

• When the key switch is first turned on all of the blue or green control panel indicator lights will turn on for one second for an operational test.
• A light indicator means that a system is on and running, or has been enabled and is ready to switch on when the drive pedal is moved into forward or reverse.
• The indicators will be off when the system is disabled or switched off.

• Scrub On/Scrub Mode Select Indicator:
  • The left side indicator will light when the normal scrub mode is selected.
  • The right side indicator will light when the heavy scrub mode is selected.
  • Both the right and left indictors will light when the extreme scrub mode is selected.
  • Both the right and left indictors will be off when the scrub system is off.
• Scrub Off Indicator:
  • The indicator will light to indicate that the scrub system is off and is ready to be activated.
  • The indicator will be off when the scrub system is enabled and/or switched on.
• Solution System Indicator:
  • The indicator will light when the solution system is enabled and/or is switched on.
  • The indicator will be off when the solution system is off.
  • The indicator will flash when the solution tank (liquid level) float switch senses a low solution level.
• Detergent System Indicator:
  • The indicator will light when the detergent system is enabled and/or is switched on.
  • The indicator will be off when the detergent system is off.

  Note: The control board automatically recognizes that the machine has an operational detergent system through its wiring harness connection.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‌‍‌​​​‌​‍‍​‍‌​‌⁠‌⁠‍‌​‍‌‌⁠​‌‍⁠​‌⁠​​‍

• Vacuum/Wand Indicator:
  • The indicator will light when the vacuum system is enabled and/or is switched on.
  • The indicator will be off when the vacuum system is off.
  • The indicator will flash when the vacuum system is operating in the time delay shutdown mode (normally five to 10 seconds).
• Maximum Scrub Speed Indicator:
  • The indicator will light when the maximum 100% transport speed during scrubbing is enabled.
  • The indicator will be off when normal scrub speed is enabled.
• Traction Control Indicator:
  • The indicator will light when the traction control mode is enabled.
  • The indicator will be off when the traction control mode is disabled.
• Side Broom On/Down Indicator:
  • The indicator will be on when the side brooms are in the down working position, enabled and switched on.

• The indicator will be off when the scrub system is switched off and the brooms are in the raised position.
• EcoFlex Indicator:
  • The (green) indicator will be on when the EcoFlex™ low-concentration detergent mode is enabled.
  • The (green) indicator will flash when the EcoFlex™ burst of power mode is enabled.
  • The (green) indicator will be off when the EcoFlex™ full-concentration detergent mode is enabled.

Note: When the recovery tank becomes full (when in the auto scrub mode), the vacuum motors and all other systems shut off except the drive motor. The LCD on the dash panel will display the full tank icon.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‌‍‍​​​‌​‍‍​‌‌‌‍‍‍‍‌⁠​‍⁠⁠​‍‍​​⁠​⁠⁠​‌

Control panel display

The control panel display is a liquid crystal display (LCD) that shows the hour meter, battery charge indicator, solution flow rate and scrub pressure. If the detergent system is enabled, the display will also show the detergent system indicator and the current detergent/solution ratio.

If an A2 Control Board error occurs, the display will show a wrench icon to indicate an error, and display a two-digit error code number. If more than one error exists, the display will sequence through the error codes at one-second intervals. (Refer to the Control System section for a list of the A2 Control Board error codes.)

Caution displays

If the recovery tank is full, the display will show a caution symbol and the tank full icon.

If the battery charge level falls to a critical level, the display will show a caution symbol and the battery-low icon.

Circuit breakers

The machine circuit breakers are located on the panel to the left of the Operator seat.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‌‍⁠​​​‌​‍‍​‍‍⁠⁠‌‍‍⁠‍‍‌‌‍​​​​⁠​‍‍‌‌⁠

General maintenance

Maintenance after use

1. When finished scrubbing, press the Scrub Off Switch. This will automatically raise the scrub deck and squeegee, and switch off the solution, detergent and vacuum systems.
2. Drive the machine to a service area for daily maintenance, and check the machine for any additional maintenance or service that may be needed.
3. To empty and clean the solution tank:
   3. a. Remove the Solution Tank Drain Hose from its storage clamp.
   3. b. Direct the Solution Tank Drain Hose to a designated disposal site and remove the Solution Tank Drain Hose Plug.
   3. c. Rinse the tank with clean water.
4. To empty and clean the recovery tank:
   4. a. Pull the Recovery Tank Drain Hose from its storage area.
   4. b. Direct the Recovery Tank Drain Hose to a designated disposal site and remove the Recovery Tank Drain Hose Plug. (Hold the end of the Recovery Tank Drain Hose above the water level in the tank to avoid sudden, uncontrolled wastewater flow.) The Recovery Tank Drain Hose can be squeezed to regulate the flow.
   4. c. Rinse the recovery tank with clean water.

4. 4. d. Inspect the Solution Tank Drain Hose, Recovery Tank Drain Hose and Vacuum Hose for wear or damage. Replace the if kinked or damaged.
5. Remove the brushes or pad holders. Rinse the brushes or pads in warm water and hang up to dry.
6. Remove the squeegee, rinse it with warm water, then reinstall.
7. Remove the Hopper on cylindrical systems and clean thoroughly. You can remove the Hopper from either side of the machine by removing the side skirt, tilting the Hopper up and away from housing, then pulling the Hopper out.
8. Check the following maintenance schedule and perform any required maintenance before you store the machine.

Maintenance schedule

* Inspect the vacuum motor carbon brushes every 300 operating hours. Check the brush and drive motor carbon brushes every 500 operating hours.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‌⁠​​​​‌​‍‍​‌‍‍⁠​‌⁠⁠‌​‍‍​‌‍‍‍⁠‌‍⁠⁠‍⁠

Note: Refer to the individual machine sections in this manual for more detail on maintenance and service repairs.

9. Store the machine indoors in a clean, dry place. Keep the machine from freezing. Leave the tanks open to air them out.
10. Turn the key switch off (O) and remove the key.

Machine lubrication

Once a month:‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‌⁠‌​​​‌​‍‍​‍⁠‍​​​⁠​​‍‌‌⁠‌‌⁠⁠​‌‍⁠⁠‍‍

• Pump a small amount of grease into each grease fitting on the machine as shown until grease seeps out around the bearings.
• Apply light machine oil to the components shown.

Apply grease to:

• Squeegee Caster Wheel Axle and Pivot
• Steering Wheel Shaft Universal joint
• Steering Chain
• Squeegee mount angle adjustment knob threads

Apply light machine oil to:

• Squeegee tool end wheels
• Recovery Tank release latch
• Brake Pedal (parking brake) linkage

The Lubrication Points drawing carries these labels: Grease (four places), Oil (three places) and Grease or Anti-seize (two places).

PM check list - SC6500

Form fields: Customer, Address, City, ST, Zip, Model, Serial, Hours (blank lines to fill in).‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‌⁠‍​​​‌​‍‍​​‌​‍⁠‍‌‌​‌‍‌⁠​⁠​​‌​​​‌‌⁠

Work Completed By: ____________ Acknowledged By: ____________‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‌⁠⁠​​​‌​‍‍​‌​⁠‌​‍⁠‍⁠​⁠‌‍‌​‍⁠​⁠⁠‍⁠‍​

Date: ____________ Date: ____________

Corrected an obvious misprint: the column heading on page 31 is printed as “(Circult)” (now “Circle”, as on page 30).

Chassis system

Major chassis components

The part shown at the bottom of the drawing is for 45 in / 48 in / 1300mm models only.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‍​​​​​‌​‍‍​​‌⁠​‌‌​‌​​⁠⁠‌​‌​‌​⁠‍‌​⁠⁠

Control system

Functional description

Overview

The control system consists of the A2 Control Board Assembly, the A3 Switch/Display Panel Assembly and associated sensors and circuitry.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‍​‌​​​‌​‍‍​‍‌​‌‍‌‌‌⁠‌⁠‌‍⁠‍⁠⁠‌‌⁠​‍‍‍

A2 control board assembly

The A2 Control Board Assembly, sometimes referred to the main controller, communicates with the Curtis A1 Speed Controller and the A3 Switch/Display Panel Assembly to coordinate the operation of the various machine systems. The A2 Control Board Assembly is fastened to the Electrical Mount behind the electrical panel cover assembly to the left of the Operator seat.

One primary function of the A2 Control Board Assembly is to position the scrub brushes relative to the floor surface using a lift actuator motor. The A2 Control Board Assembly continuously monitors the brush motor current draw to maintain the desired scrub pressure on the floor.

• If the brush motor current drops below the desired range, the A2 Control Board Assembly switches on the lift actuator motor to move the scrub deck downward until the brush motor current draw is within the correct range for the scrub pressure selected.
• If the brush motor current rises above the desired range, the A2 Control Board Assembly switches on the lift actuator motor to lift the scrub deck upward until the brush motor current draw is again within the correct range for the scrub pressure selected.

Note: Refer to the Scrub System section in this manual for a complete explanation of scrub deck operation.

A secondary function of the A2 Control Board Assembly is to detect any system failures and display the corresponding error code on the display panel, or store it in the control board’s recall memory mode. The error codes are used to help service technicians determine the fault and to guide in repairing a specific system malfunction quickly.

Note: See the Troubleshooting section for further information.

The A2 Control Board Assembly also allows you to change program settings for a set of specific machine functions. See the Main Control Programming Options section in this manual for further information.

A3 switch/display panel assembly

The A3 Switch/Display Panel Assembly is the user interface that includes the various system switches and buttons, and the control panel display. The A3 Switch/Display Panel Assembly sends the operator inputs via a CAN BUS to the A2 Control Board Assembly.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‍​‍​​​‌​‍‍​‌​​‌‌‌‍​​⁠⁠‍⁠‍‌⁠​​‍‍​⁠​⁠

Circuit description

The A2 Control Board Assembly is connected by several inputs to battery negative:

The A2 Control Board Assembly gets positive battery voltage from two inputs:

• When the key switch, seat switch and battery interlock are closed, positive voltage is supplied to the A2 Control Board Assembly.
• When the key switch is closed, positive voltage is supplied to the coil side of contactor K5. When K5 contacts close, positive voltage is supplied to the A2 Control Board Assembly.

The A3 Switch/Display Panel Assembly gets voltage from two outputs on the A2 Control Board Assembly. The A3 Switch/Display Panel Assembly communicates with the A2 Control Board Assembly via a CAN BUS connection (CAN H and CAN L).

Main control programming options

Fault recall mode

Whenever the A2 Control Board Assembly detects an electrical system error or fault, one or more error codes are displayed and stored by the A2 Control Board Assembly. You can recall error codes (if any) from previous machine operation for troubleshooting purposes, To recall stored error codes:

1. Turn the key switch off.
2. Press and hold the solution switch.
3. While holding the solution switch, turn the key switch on.
4. Continue to hold the solution switch until the solution system indicator turns on.
5. Release the solution switch. The solution system indicator turns off and the scrub off indicator will light. The display will show a wrench icon indicating that you are in fault recall mode.
   • If there are no previous error codes stored, the display will show the no-fault wrench icon (a wrench with a short line through it) asking you to reset the machine (no fault). Skip to step 7.
   • If error codes have been stored, the display will show the wrench icon and error number(s) next to the wrench. If more than one error code is stored, the display will toggle through all the errors stored.
6. • If you want to save the codes, skip to step 7.
   • To clear the stored error codes, press the scrub off switch. The display will now show key switch icon asking you to reset the machine.
7. To exit the fault recall mode, turn the key switch off.

To select the battery used in the machine

Note that the factory default is Standard (LVC = 31V)‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‍​⁠​​​‌​‍‍​‍‌‌​‍‌⁠‍‌‌‍⁠‌‍​‍‍⁠⁠‍‌‌‌‌

1. Turn the key switch off.
2. Press and hold the scrub off switch.
3. While holding the scrub off switch, turn the key switch on.
4. Continue to hold the scrub off switch until the Scrub Off LED indicator turns on.
5. Release the switch. The display will now show BATTERY.
6. Press the scrub on switch to select the type of battery that is in the machine.
7. Press the scrub off switch to save the new setting and display the key switch icon.
8. Turn the key switch off. The new setting will be saved until changed again.

To restore the scrub pressures to the factory default settings

1. Turn the key switch off.
2. Press and hold the scrub on switch.
3. While holding the scrub on switch, turn the key switch on.
4. Continue to hold the scrub on switch until the display shows key switch icon. The factory default scrub pressures have now been restored.
5. Turn the key switch off.

To enable/disable the fault detection

Note that the factory default for fault detection is OFF.

You can enable or disable “open circuit” fault detection with this setting. If the setting is set to “off” the controller will still detect and set faults for over current conditions.

To turn the fault checking on or off:

1. Turn the key switch off.
2. Press and hold both the scrub off switch and solution switch.
3. While holding both switches, turn the key switch on.
4. Continue to hold both switches until both switch indicators turn on. The display will show a wrench icon indicating fault detection mode.
5. Release both switches. The solution system indictor light will blink and the scrub off indicator will stay on.
6. Press the solution switch to toggle the fault detection between enabled/on (wrench icon with no cross) or disabled/off (wrench icon with cross).
7. Press the scrub off switch to save the new setting and display the key switch icon.
8. Turn the key switch off. The new setting will be saved until changed again.

To display the control board revision level

1. Turn the key switch off.
2. Press and hold both the scrub off switch and traction control switch.
3. While holding both switches, turn the key switch on.
4. Continue to hold both switches until the scrub off and traction control indicators light.
5. Release both switches. The scrub off and traction control indicators will switch off. The display will show the MAIN REVISION of the A2 control board assembly, the DISPLAY REVISION of the A3 switch/display panel assembly and the key switch icon.
6. Turn the key switch off.

Monitor mode

The control system allows the five machine settings listed below to be quickly checked in the monitor mode to view the machine’s specific setup. To enter the monitor mode and view the current machine settings:‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‍‌​​​​‌​‍‍​⁠‌⁠‍⁠​‍⁠‍​‍​‌​⁠​​‍‍⁠‍‍⁠⁠

1. Turn the key switch off.
2. Press and hold the detergent switch.
3. While holding the detergent switch, turn the key switch on.
4. Continue to hold the detergent switch until the detergent system indicator switches on.
5. Release the detergent switch. The display will show the following current machine programmed settings:
   • Scrub deck type and size,
   • Detergent mode on/off,
   • Fault detection on/off,
   • Vacuum motor selection – VACUUM–SINGLE (one motor) or VACUUM–DUAL (two motors).
6. To exit the monitor mode, turn the key switch off.

Scrub deck down time adjustment

Note that the factory default deck down time is two seconds.

When scrub on switch is pressed, the control board will automatically lower the deck for two seconds. The time that the deck is lowered is adjustable from one second to three seconds in 0.1-second increments.

To adjust the scrub deck down time:

1. Turn the key switch off.
2. Press and hold the scrub on and solution switches.
3. While holding both switches, turn the key switch on.
4. Continue to hold both switches until both switch indicators turn on.

5. Release both switches. The display will now show a clock icon in the upper left corner with a number indicating the scrub deck down time period.
6. Press the scrub on switch to increment the time period. Each press of the switch increments the scrub deck down time 0.1 seconds. For example, the time will increment from 2.0 seconds to 2.1 seconds, and so on. The deck down times range from 1.0 to 3.0 seconds.
7. Press the scrub off switch to save the new setting and display the key switch icon.
8. Turn the key switch off. The new setting will be saved until changed again.

Normal (light) scrub setting adjustment

Note that the factory default settings for the normal scrub setting are: Scrub pressure – one bar, Solution flow rate – one bar.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‍‌‌​​​‌​‍‍​‌⁠⁠​‌‍⁠‍‌​‌⁠⁠‍‌‍​‌⁠​‌‍​‍

The scrub pressure and solution flow rate for the normal scrub setting can be programmed to better suit a particular application. This allows you to select a higher solution flow rate with normal scrub pressure, or a normal solution rate with heavier scrub pressure, etc., as the normal scrub setting. To change the normal scrub settings:

1. Turn the key switch off.
2. Press and hold the scrub on and scrub speed switches.
3. While holding both switches, turn the key switch on.
4. Continue to hold both switches until the scrub speed indicator turns on and the normal scrub on indicator blinks.
5. Release both switches. The display will now show a scrub icon (either disc or cylindrical) with the current scrub pressure setting.
6. Press the scrub on switch to increment the scrub pressure setting as shown by the number of bars in the display.
7. Press the scrub off switch to save the new scrub pressure setting and move to the solution flow rate setting. The display will now show the solution icon with gauge. The normal scrub indicator will stop blinking and the solution system indicator will blink.
8. Press the solution switch to increment the solution flow rate as shown by the number of bars in the display.
9. Press the scrub off switch to save the new solution flow rate setting and move to the detergent concentration setting. The display will now show the detergent icon with a 0, + or – next to it. The solution system indicator will stop blinking and the detergent indicator will blink.
10. Press the detergent switch to scroll through and select the 0, + or – character in the display.
    • Selecting 0 will not change the detergent concentration in the detergent ratios.
    • Selecting + will increase the detergent concentration in the detergent ratios by 10 percent.
    • Selecting – will decrease the detergent concentration in the detergent ratios by 10 percent.
11. Press the scrub off switch to save the detergent concentration setting and display the key switch icon.
12. Turn the key switch off. The new settings will be saved until changed again.

Heavy scrub setting adjustment

Note that the factory default settings for the heavy scrub setting are: Scrub pressure – two bars, Solution flow rate – two bars.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‍‌‍​​​‌​‍‍​​​‌‍​‌‍‍⁠​‌‌​‍‌⁠​⁠‍​⁠‍​‌

The scrub pressure and solution flow rate for the heavy scrub setting can be programmed to better suit a particular application. This allows you to select a higher solution rate with heavy scrub pressure, or a normal solution rate with heavy scrub pressure, etc., as the heavy scrub setting. To change the heavy scrub settings:

1. Turn the key switch off.
2. Press and hold the scrub on and detergent switches.
3. While holding both switches, turn the key switch on.
4. Continue to hold both switches until the detergent indicator turns on and the heavy scrub indicator blinks.
5. Release both switches. The display will now show a scrub icon (either disc or cylindrical) with the current scrub pressure setting.
6. Press the scrub on switch to increment the scrub pressure setting as shown by the number of bars in the display.
7. Press the scrub off switch to save the new scrub pressure setting and move to the solution flow rate setting. The display will now show the solution icon with gauge. The solution system indicator will blink.
8. Press the solution switch to increment the solution flow rate as shown by the number of bars in the display.
9. Press the scrub off switch to save the new solution flow rate setting and move to the detergent concentration setting. The display will now show the detergent icon with a 0, + or – next to it. The solution system indicator will stop blinking and the detergent indicator will blink.
10. Press the detergent switch to scroll through and select the 0, + or – character in the display.
    • Selecting 0 will not change the detergent concentration in the detergent ratios.
    • Selecting + will increase the detergent concentration in the detergent ratios by 10 percent.
    • Selecting – will decrease the detergent concentration in the detergent ratios by 10 percent.
11. Press the scrub off switch to save the detergent concentration setting and display the key switch icon.
12. Turn the key switch off. The new settings will be saved until changed again.

Extreme scrub setting adjustment

Note that the factory default settings for the extreme scrub setting are: Scrub pressure – three bars, Solution flow rate – three bars.

The scrub pressure and solution flow rate for the extreme scrub setting can be programmed to better suit a particular application. This allows you to select a higher solution rate with extreme scrub pressure, or a normal solution rate with extreme scrub pressure, etc., as the extreme scrub setting. To change the extreme scrub settings:

1. Turn the key switch off.
2. Press and hold the scrub on and vacuum/wand switches.

3. While holding both switches, turn the key switch on.
4. Continue to hold both switches until the vacuum/wand indicator turns on, and the normal and heavy scrub indicators blink.
5. Release both switches. The display will now show a scrub icon (either disc or cylindrical) with the current scrub pressure setting.
6. Press the scrub on switch to increment the scrub pressure setting as shown by the number of bars in the display.
7. Press the scrub off switch to save the new setting and move to the solution flow rate setting. The display will now show the solution icon with gauge. The normal and heavy scrub indicators will stop blinking and the solution indicator will blink.
8. Press the solution switch to increment the solution flow rate as shown by the number of bars in the display.
9. Press the scrub off switch to save the new solution flow rate setting and move to the detergent concentration setting. The display will now show the detergent icon with a 0, + or – next to it. The solution system indicator will stop blinking and the detergent indicator will blink.
10. Press the detergent switch to scroll through and select the 0, + or – character in the display.
    • Selecting 0 will not change the detergent concentration in the detergent ratios.
    • Selecting + will increase the detergent concentration in the detergent ratios by 10 percent.
    • Selecting – will decrease the detergent concentration in the detergent ratios by 10 percent.
11. Press the scrub off switch to save the detergent concentration setting and display the key switch icon.
12. Turn the key switch off. The new settings will be saved until changed again.

Scrub speed switch lockout

Note that the factory default setting for the scrub speed switch is FAST/SLOW - ENABLE.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‍‌⁠​​​‌​‍‍​‍⁠‌‍​‍​‌‌‍‍⁠⁠‌‍‌‌‌⁠​‍⁠‍‌

The control system is programmed to limit the maximum travel speed while scrubbing to a value less than that allowed when driving and not scrubbing. Pressing the scrub speed switch on the control panel will override this speed limiting feature and allow scrubbing at a the higher speed. If you wish to prevent scrubbing at this faster speed, you can disable the scrub speed switch override feature. To disable the scrub speed switch override feature:

1. Turn the key switch off.
2. Press and hold the scrub speed switch.
3. While holding the scrub speed switch, turn the key switch on.
4. Continue to hold the scrub speed switch until the scrub speed and scrub off indicators both turn on.
5. Release the scrub speed switch. The scrub speed indictor light will blink.
6. Press the scrub speed switch to enable or disable the scrub speed switch override feature. FAST/SLOW - ENABLE means that the high-speed scrub feature is turned on. FAST/SLOW - DISABLE means that the high-speed scrub feature is turned off.
7. Press the scrub off switch to save the setting and display the key switch icon.
8. Turn the key switch off. The new setting will be saved until changed again.

Detergent system selection mode

1. Turn the key switch off.
2. Press and hold the scrub off switch and the detergent switch.
3. While holding both switches, turn the key switch on.
4. Continue to hold both switches until both switch indicators turn on.
5. Release both switches. The scrub off indicator will stay lit and the detergent system indicator will blink. The display will now show a detergent bottle in the upper left corner indicating the detergent selection mode.
6. Press the detergent switch to select between a normal detergent bottle icon indicating that the detergent system is activated, or a detergent bottle with a cross through it indicating that the detergent system is not activated.
7. Press the scrub off switch to save the new setting and display the key switch icon.
8. Turn the key switch off. The new setting will be saved until changed again.

EcoFlex™ mode selection

Note that the factory default setting for the EcoFlex™ Mode is OFF.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‍‍​​​​‌​‍‍​‌​‍​⁠‌⁠⁠‍​‍⁠⁠‍⁠⁠​‌‌‌​⁠​‍

1. Turn the key switch off.
2. Press and hold the EcoFlex™ button.
3. While holding the button, turn the key switch on.
4. Continue to hold the button for two seconds until the EcoFlex™ and scrub off indicators turn on.
5. Release the EcoFlex™ button. The display will now show the ECOFLEX MODE/OFF, ECOFLEX MODE/MODE 1 and ECOFLEX MODE/MODE 2 menu.
6. Press the EcoFlex™ button to scroll through the menu and select the desired ECOFLEX MODE. On the SC6500, there is no difference in machine operation whether Mode 1 or Mode 2 is selected.
7. Press the scrub off switch to save the setting and display the key switch icon.
8. Turn the key switch off. The new setting will be saved until changed again.

Vacuum motor configuration option

Note that the factory default setting for the vacuum motor configuration is SINGLE (one vacuum motor).

All rider scrubber models covered in this manual can be equipped with optional dual vacuum motors. The A2 control board assembly must be programmed for the number of vacuum motors installed so that the current overload protection will function correctly. To select the vacuum motor configuration:

1. Turn the key switch off.
2. Press and hold the scrub system off and vacuum/wand switches.
3. While holding both switches, turn the key switch on until the scrub off and vacuum/wand indicators light.

4. Release both switches. The vacuum/wand indictor will flash. The control panel display will now indicate the vacuum motor setting.
5. Press the vacuum/wand switch to toggle between VACUUM - SINGLE for a single vacuum motor or VACUUM - DUAL for two vacuum motors.
6. Press the scrub off switch to save the setting and display the key switch icon.
7. Turn the key switch off. The new setting will be saved until changed again.

Recovery tank full detection enable/disable

Note that the factory default setting for the recovery tank full detection is ENABLE.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‍‍‌​​​‌​‍‍​⁠‍‍‌‌​⁠​‌⁠‌‌​‍⁠​​‍⁠​‌‌⁠​

The SC6500 is equipped with a feature that will automatically shut off the vacuum and scrub systems and display a recovery tank full icon on the control panel display when the recovery tank becomes full. If problems are encountered with the vacuum shutoff feature, such as the vacuum shutting off even when the recovery tank is not full, this feature can be turned off. To turn this feature on (enable) or off (disable):

1. Turn the key switch off.
2. Press and hold the vacuum/wand switch.
3. While holding the vacuum/wand switch, turn the key switch on.
4. Continue to hold the vacuum/wand switch until the vacuum/wand indicator turns on.
5. Release the vacuum/wand switch. The vacuum/wand indictor will blink and the scrub off indicator will turn on. The display will now show a text message REC TANK FULL DETECT/ENABLE or DISABLE.
6. Press the vacuum/wand switch to toggle between ENABLE or DISABLE. ENABLE means that the automatic shutoff feature is turned on. DISABLE means that the automatic shutoff feature is turned off.
7. Press the scrub off switch to save the setting and display the key switch icon.
8. Turn the key switch off. The new setting will be saved until changed again.

Solution flow in reverse enable/disable

Note that the factory default setting for the solution flow in reverse option is ENABLE.

The solution flow is programmed to dispense solution when the machine backing up. To disable solution flow when the machine moves in reverse:

1. Turn the key switch off.
2. Press and hold the EcoFlex™ button and the solution switch.
3. While holding both the button and switch, turn the key switch on.
4. Continue to hold the button and switch until the solution system and vacuum/wand indicators turn on.
5. Release the button and switch. The vacuum/wand indicator will turn off, the solution system indictor will blink and the scrub off indicator will turn on. The display will now show the message SOLUTION IN REVERSE/ENABLE or DISABLE.
6. Press the solution switch to toggle between SOLUTION IN REVERSE ENABLE or DISABLE. If you select ENABLE, the solution flow will stay on when the machine is moving in reverse. If you select DISABLE, solution flow will stop when the machine is moving in reverse.

7. Press the scrub off switch to save the setting and display the key switch icon.
8. Turn the key switch off. The new setting will be saved until changed again.

Indicator LED intensity selection option

Note that the factory default setting for the indicator LED intensity is normal.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‍‍‍​​​‌​‍‍​‌​‌‍​‌‌‍⁠⁠⁠⁠⁠⁠⁠‌‌‍‌⁠⁠⁠⁠‌

To change the intensity of the LEDs in the control panel indicators.

1. Turn the key switch off.
2. Press and hold the vacuum/wand and scrub speed switches.
3. While holding both switches, turn the key switch on.
4. Continue to hold both switches until the vacuum/wand and scrub speed indicators turn on. The display will now show a light bulb icon in the upper left corner indicating the LED light intensity selection.
5. Release both switches. The scrub speed and scrub off indicators will light and the vacuum/wand indicator will blink.
6. Press the vacuum/wand switch to select between the normal intensity or extra bright intensity levels.
7. Press the scrub off switch to save the setting and display the key switch icon.
8. Turn the key switch off. The new setting will be saved until changed again.

Detergent and solution pump purge

The EcoFlex™ detergent system has two purge (flush) programs to ensure that the detergent delivery hoses and related components are kept open and clean. A general operational description in how the system functions is found in the Solution System section. To activate the maintenance purge functions:

Method 1

1. Turn the key switch off.
2. Press and hold both the detergent and solution switches.
3. While holding the switches, turn the key switch on. The display will show the purge icon, the detergent and solution pumps will run for approximately 20 seconds, then the pumps will shut off.
4. When the purge cycle is complete, turn the key switch off.

Method 2 (as described in the Instructions for Use)

1. Turn the key switch on.
2. Press and hold both the detergent and solution switches for three seconds. The detergent and solution pumps will run for approximately 10 seconds.
3. When the purge cycle is complete, turn the key switch off.

Side broom function

1. Turn the key switch off.
2. Press and hold the side broom on/down switch.
3. While holding the switch, turn the key switch on.
4. Continue to hold the switch until the side broom on/down indicator turns on.
5. Release the switch. The display will now show SIDE BROOM/ENABLE or DISABLE.
6. Press the side broom on/down switch to toggle between SIDE BROOM ENABLE or SIDE BROOM DISABLE.
7. Press the scrub off switch to save the setting and display the key switch icon.
8. Turn the key switch off. The new setting will be saved until changed again.

Side broom height adjustment

The height of the side brooms is determined by the length of time the side broom actuator runs as it lowers the side brooms. Note that:‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‍‍⁠​​​‌​‍‍​​⁠⁠⁠​‌‍‍​‍⁠​​​‍⁠​⁠‌​‌⁠⁠‌

• Increasing the side broom actuator run time lowers the side broom height.
• Decreasing the side broom actuator run time raises the side broom height.

To adjust the side broom height:

1. Turn the key switch off.
2. Press and hold the side broom on/down and scrub off switches.
3. While holding the switches, turn the key switch on.
4. Continue to hold the switches until the side broom on/down indicator, scrub off indicator and both scrub on indicators turn on.
5. Release the switches. The indicators will stay on and the display will now show the side broom actuator down run time in seconds.
6. • Press the scrub on switch to increase the side broom actuator run time and lower the position of side brooms.
   • Press the side broom on/down switch to decrease the side broom actuator run time and raise the position of side brooms.

   Note that the side broom actuator run times range from 1.0 to 3.0 seconds.

7. Press the scrub off switch to save the side broom height. The actuator will raise the brooms to their up position and the display will show a key switch icon.
8. Turn the key switch off. The machine is now reprogrammed to work with the new side broom height setting.

Display mode selection

1. Turn the key switch off.
2. Press and hold the detergent switch and EcoFlex™ button.
3. While holding the detergent switch and EcoFlex™ button, turn the key switch on.
4. Continue to hold the button and switch for two seconds until the EcoFlex™ and detergent system indicators turn on.
5. Release the button and switch. The EcoFlex™ indicator will blink and the display will show DISPLAY MODE.
6. Press the EcoFlex™ button to toggle between 1. US DISPLAY and 2. GLOBAL DISPLAY.
7. Press the scrub off switch to save the new setting and display the key switch icon.
8. Turn the key switch off. The new setting will be saved until changed again.

Service test mode

The purpose of the service test mode is to assist the service technician with numerous quick shortcut troubleshooting procedures. The service test mode allows you to control individual system components independent of the normal machine operator inputs.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‍⁠​​​​‌​‍‍​​⁠⁠‍‌​‌‍‌‍​‍⁠​⁠⁠‍​⁠‌⁠⁠‌⁠

To enter the service test mode

1. Turn the key switch off.
2. Press and hold the scrub speed and traction control switches.
3. While holding the scrub speed and traction control switches, turn the key switch on.
4. Continue to hold the scrub speed and traction control switches until the traction control indicator lights.
5. Release the scrub speed and traction control switches. The scrub speed indicator will turn off and the display will show NEUTRAL/SC-NO FAULT (speed controller - no fault). The display, switch and indicator functions in the service test mode are described below.
6. To exit the service test mode, turn the key switch off.

Service test mode display

• Speed Control Status
  • This indicator will read SC–NO FAULT (speed controller - no fault) if the status signal from the speed control is normal.
  • If a speed control fault exists, this indicator will read SC-FAULT (speed control fault). Refer to the Wheel System, Traction section for details on these codes.
• Speed Control Foot Throttle Status
  • The control panel display will read NEUTRAL when the operator foot pedal is at rest.
  • The control panel display will read FORWARD when the foot pedal is depressed in the forward direction to activate its forward drive mode functions.

Control panel switch and button functions

• The control panel display will read REVERSE when the operator foot pedal is depressed in the reverse direction to activate its reverse drive mode functions.

Scrub System Off Switch – This switch controls the scrub brush motor(s). Pressing and releasing this switch will alternately turn the brush motor(s) on and off. The scrub off indicator provides the following status information:‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‍⁠‌​​​‌​‍‍​‍⁠​‍‍​​⁠⁠​⁠⁠​‌‍⁠‌‌‌‌⁠‌‍‍

• Off - Brush motor output is off and there is no brush motor current sensed.
• Steady Blue - Brush motor output is on and there is normal brush motor current sensed.

Scrub ON/Pressure Select Switch – This switch controls the scrub deck lift actuator as follows:

• Pressing the switch the first time will switch on the actuator to lower the scrub deck. The normal scrub indicator (left blue LED) will light as the actuator is running. Once the deck reaches the down position, the normal scrub indicator will blink.
• Pressing the switch a second time will switch off the normal scrub indicator.
• Pressing the switch a third time will switch on the actuator to raise the scrub deck. The normal scrub indicator will light as the actuator is running. Once the deck reaches the up position, the normal scrub indicator will blink.
• Pressing the switch a fourth time will switch off the normal scrub indicator.

Vacuum/Wand Switch – This switch controls the squeegee lift actuator and vacuum motor(s) as follows:

• Pressing the switch the first time will switch on vacuum motor(s) and switch on the actuator to lower the squeegee. The vacuum/wand indicator will light as the actuator is running. Once the squeegee reaches the down position, the vacuum/wand indicator will blink.
• Pressing the switch a second time will switch off the vacuum/wand indicator.
• Pressing the switch a third time will switch off the vacuum motor(s) and switch on the actuator to raise the squeegee. The vacuum/wand indicator will light as the actuator is running. Once the squeegee reaches the up position, the vacuum/wand indicator will blink.
• Pressing the switch a fourth time will switch off the vacuum/wand indicator.

Side Broom On/Down Switch – This switch controls the side broom motors and side broom lift actuator as follows:

• Pressing the switch the first time will switch on side broom motors and switch on the actuator to lower the side brooms. The side broom on/down indicator will light as the actuator is running. Once the side brooms reach the down position, the side broom on/down indicator will blink.
• Pressing the switch a second time will switch off the side broom on/down indicator.

Troubleshooting

• Pressing the switch a third time will switch off the side broom motors and switch on the actuator to raise the side brooms. The side broom on/down indicator will light as the actuator is running. Once the side brooms reach the up position, the side broom on/down indicator will blink.
• Pressing the switch a fourth time will switch off the side broom on/down indicator.

Solution Switch – This switch controls the solution solenoid and solution control pump. Pressing and releasing this switch will alternately turn the solution solenoid and solution pump on and off. The solution system indicator provides the following status information:‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​‍⁠‍​​​‌​‍‍​​‍​‍​​​‌‌⁠‍⁠​⁠‌​‌‌‌​‍‌⁠‍

• Off – Solenoid and solution pump outputs are off.
• Steady Blue – Solenoid and solution pump outputs are on.

Detergent Switch – This switch controls the detergent pumps. Pressing and releasing this switch will alternately turn the detergent pumps on and off. The detergent system indicator provides the following status information:

• Off – Detergent pump output is off.
• Steady Blue – Detergent pump output is on.

Error indicator and error code display

Any error codes detected by A2 Control Board Assembly will be displayed on the control panel display as they occur. If more than one error exists, the display will sequence through the error codes at one-second intervals. The error will display as a mechanical wrench symbol followed by a two-digit code. For example, wrench symbol 29 as shown in the adjacent drawing would be an open vacuum motor error.

Error codes

Error codes

Error codes

Error codes

Error codes

Error codes

* Short Circuit definition:

• A short circuit is a parallel path of very low resistance, often caused accidentally.
• With low resistance there is an excessive amount of current.
• The excessive current will either melt the wires or open a fusible link.

** See Service Test Mode in this manual for further troubleshooting information.

*** See the Main Control Programming Options section to activate the Brush Type Selection function.

Removal and installation

A2 control board assembly

1. Remove the electrical panel cover assembly (located to the left of the operator position). Make sure to unplug the fan assembly before removing the electrical panel cover assembly from the machine.
2. Disconnect the electrical connectors from the A2 Control Board Assembly.
3. Remove the five screws holding the A2 Control Board Assembly to the Electrical Mount and remove the A2 Control Board Assembly from the machine.
4. Install the A2 Control Board Assembly by following the above steps in reverse order.

Specifications

I/O table with shop measurements

A2 control board assembly

* It is difficult to validate the signal using a voltmeter. An LED test light such as a logic probe is a better indicator.

** The Solution Pump (-) line provides a switched ground return for the pump. When the solution pump is on, a 5KHz signal with a varying duty cycle and a peak voltage of 36 volts will appear between this pin and B+. Measuring with a DC voltmeter will give a signal in the range of 6 to 27 volts. Changing the flow rate solution bars on the LCD should produce a relative increase or decrease of the meter reading.

Electrical system

The electrical system chapter contains information on the battery and electrical components which are foundational such as circuit protection, wiring harnesses and electrical items that do not have a more clear home in another chapter. For instance, see the solution system chapter for information on the solution solenoid.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​⁠‍⁠​​​‌​‍‍​​‍‌‌‍‌‍⁠⁠‌‌‌​⁠‍⁠⁠‍‍‌‌‌​⁠

Functional description

Overview

This section includes information on battery installation and maintenance, a description of the low-voltage cut-out function, and descriptions of the battery condition displays.

• For information on the A2 Control Board Assembly, refer to the Control System section.
• For information on the A1 (Curtis) Speed Controller, refer to the Wheel System, Traction section.

Low-voltage cut-out feature

All models discussed in this manual are equipped with a low-voltage cutout feature to prevent over-discharging of the batteries. When a machine’s battery pack voltage falls below a specifically defined threshold (voltage settings), the scrub system automatically shuts down. The drive motor will still operate in the low-voltage cut-out mode to allow the machine to be driven to a charging location.

The low-voltage cut-out level is adjustable. The standard lead-acid battery (wet cell) setting is 1.72 volts per cell. The alternate maintenance-free battery (gel cell) setting is 1.81 volts per cell. The standard lead-acid battery setting is factory-selected and should be used unless the battery manufacturer specifies the higher cut-out voltage.

Service Note: A minimum recharge voltage of 2.13 volts per cell must be reached to allow the scrub and solution systems to function again (reset). A 36-volt battery pack must increase to a 38.6-volt minimum.

Battery condition indicator

The battery indicator displays the state of battery charge. Five vertical bars indicates a fully-charged battery after a complete charging cycle. The battery indicator will retain the state-of-charge even if the key switch has been turned off. The state-of-charge indicator is reset to full charge when the batteries have been recharged. It is also possible to choose between two different low-voltage thresholds depending on whether maintenance-free or standard (lead-acid) batteries are being used (Have a qualified service engineer perform this selection*.)

Note: The following table represents how many “bars” are displayed in the battery indicator icon based on the actual battery voltage.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​⁠⁠​​​​‌​‍‍​⁠‌​‌⁠‌​​​‌‌​⁠‍‌​‍‌‍‍⁠⁠⁠‌

Component locations

Battery location

The Batteries are located in the battery compartment behind the operator seat and underneath the recovery tank.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​​⁠⁠⁠​​​‌​‍‍​‍‍‍‍​​‍‌‍​‍⁠‍​‌‍‌‍​​‍⁠⁠‌

The Battery Disconnect is mounted on the right side of the operator seat.

Connector pin-outs

J1 connects to A2 control board

Connector shown: AMP 770680-1.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌​​​​​​‌​‍‍​‌⁠​​‍⁠⁠‍‍​⁠‍‌‌‍‌⁠​⁠​​⁠⁠⁠

J2 connects to A2 control board

Connector shown: AMP 770680-4.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌​​‌​​​‌​‍‍​‍⁠‍⁠⁠‌⁠‌​‌​⁠‍‌‍⁠⁠​⁠​‌‍⁠‌

J3 connects to A3 display panel

Connector shown: MOLEX 39-01-3048.

X6 connects to A1 speed controller

Connector shown: AMP 776164-1, black.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌​​‍​​​‌​‍‍​‌​⁠‌‍‌‍​‍‌​‌​‍‍‌⁠⁠⁠⁠​⁠​‍

X7 connects to drive motor

X8 connector for Curtis programmer

X10

Connects to S3 Battery Interlock Switch X9 if equipped. If not, connects to X51 Jumper‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌​​⁠​​​‌​‍‍​​​⁠‍‍​​​‍​​‌​‌‍‌‍⁠‍‌⁠⁠​‌

X12 connects to H2 flashing lamp X11

X13 connects to M12 solution control pump X14

X16 connects to L1 solution solenoid valve X15

X18 connects to M2 brush actuator X17

X20 connects to M3 squeegee actuator X19

X22 connects to M4 side broom actuator X21

X29 connects to M7 left side broom motor X27

X30 connects to M8 right side broom motor X28

X32

X41 connects to R2 scrub deck sensing resistor X40

X43 connects to S5 solution tank float switch X42

X49 connects to X48 connector of vacuum motor wiring harness

X51

Connector, Battery Interlock Switch Jumper (used when there is not an optional interlock switch)‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌​‍​​​​‌​‍‍​⁠​⁠⁠‍‌‍‍‍⁠‌‍‍⁠⁠‍​‍‍⁠‍‍‌⁠

X55 connects to M15 accessory pump (optional) X54

X59 connects to telematics connector jumper X59A

X59A telematics connector jumper

X60 (Deutsch DTM04-6P) connects to X61

X61 (Deutsch DT M06-6s) connects to X60

Maintenance and adjustments

Wet-cell battery maintenance

Correct maintenance of electric vehicle batteries can greatly extend their life. Well-maintained batteries may last up to three years, but failure after one year is common if maintenance has been inadequate.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌​‍‍​​​‌​‍‍​​​‌⁠​​​⁠​‌‍⁠​​‍‌⁠​⁠‌‍‌‌‍

There are three simple rules for good battery maintenance:

• Maintain the correct electrolyte level (check weekly). Use distilled water in batteries whenever possible. If batteries are discharged, add just enough water to cover the plates in each cell. If batteries are fully-charged, fill each cell to the bottom of the filler tube. Do not overfill the batteries! Do not add acid to batteries!
• Keep the batteries charged (charge weekly). Batteries should be charged each time that a machine is used for more than one hour. The battery compartment cover should be open during charging to avoid a concentrated buildup of hydrogen gas. Operators should follow the instructions provided with their specific battery charger to determine how long the batteries should be charged. Even when a machine is stored, the batteries should be charged once a month to prevent the batteries from “sulfating”. Almost all battery caps are vented, so there’s no need to loosen or remove them for charging.
• Keep the batteries clean (check and clean monthly). Use a damp cloth to wipe dirt from the top of the batteries. Battery terminals must be clean and tight. If the tops of the batteries are wet after charging, the batteries have probably been overfilled or overcharged.

Note: If there is acid on the batteries, wash the tops of the batteries with a solution of two tablespoons of baking soda to one quart (about 1 liter) of water.

Checking the battery water level

1. Check the water level of the batteries at least once a week.
2. After charging the batteries, remove the vent caps and check the water level in each battery cell. Use distilled or demineralized water in a battery filling dispenser (available at most auto parts stores) to fill each cell to the level indicator (or to approximately 3/8 in (10 mm) over the top of the separators). Do not overfill the batteries!
   CAUTION! Acid can spill onto the floor if the batteries are overfilled.
3. Tighten the vent caps.
4. Wash the tops of the batteries with a solution of baking soda and water. Use a mixture of two tablespoons of baking soda to one quart (about 1 liter) of water).

Charging wet-cell batteries

Charge the batteries each time the machine is used, or when the battery indicator is reading less than full.

To charge the batteries

1. Disconnect the machine battery connector.
2. Open the side access panel and push the connector from the charger into the battery connector.
3. Follow the instructions on the battery charger.
4. After charging the batteries, check the fluid level in all battery cells. Add distilled water if necessary to bring the fluid level up to the bottom of the filler tubes.
   WARNING!

   • Do not fill the batteries before charging.
   • Charge the batteries in a well-ventilated area.
   • Do not smoke while servicing the batteries.

When servicing batteries

• Remove all jewelry.
• Do not smoke.
• Wear safety glasses, rubber gloves and a rubber apron.
• Work in a well-ventilated area.
• Do not allow tools to touch more than one battery terminal at a time.
• ALWAYS disconnect the negative (ground) cable first when replacing batteries to prevent sparks.
• ALWAYS connect the negative cable last when installing batteries.

Troubleshooting

Battery testing

A battery problem is usually recognized by the machine operator as a decrease in the machine’s running time. This condition is usually caused by one or more “dead cells” in the battery system – that is, one or more cells that are putting out less voltage than the other cells.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌​⁠​​​​‌​‍‍​‍​⁠​‍‍‌‌‍‌⁠​⁠⁠‍⁠⁠​‍‍​​⁠⁠

Note: Always charge batteries before testing.

There are two ways to find a dead cell:

• Use a voltmeter to check the voltage of each battery with the scrub and drive motors running. The battery with the dead cell will read 1 or 2 volts lower than the other batteries in the system.
• Use a hydrometer to check the specific gravity (or “state of charge”) of the fluid in each cell. A dead cell is one that reads 50 points (or more) lower than the other cells.

If the batteries in the machine are more than one year old, it’s usually best to replace the whole set rather than replacing just one battery.

General troubleshooting

Removal and installation

To install the batteries

1. Remove the batteries from their shipping crate and carefully inspect them for cracks or other damage. If damage is evident, contact the carrier that delivered them, or the battery manufacturer, to file a damage claim.
2. Turn the key switch off and remove the key.
3. Remove the recovery tank from the machine. (Refer to the Recovery System/Removal and Installation/Recovery Tank section.)
4. Your machine comes from the factory with enough battery cables to install six 6-volt batteries. Using at least two people and an appropriate lifting strap, carefully lift the batteries into the battery compartment and arrange them exactly as shown. Secure the batteries as close to the front of the machine as possible. If installing a monoblock battery, use an overhead hoist.
5. Install the battery cables as shown. Position the cables so the battery caps can be removed easily for battery service.

Text printed above the layouts: “450 AH @ 20 HR RATE, 1300 lb (590 kg), (6) max”. “Battery Disconnect” is marked. Six-battery layout labels: 56407358 and “395AH@20HR 56388582”. Monoblock layout: “36V”, “450AH@20HR 56409691” and “480AH@5HR (EU only)”. The arrow marks the front of the machine.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌​⁠‌​​​‌​‍‍​‍‌‌⁠‌⁠⁠‌‍‍‌⁠‌‍⁠​​⁠⁠‍⁠‍‌⁠

6. Carefully tighten the nut in each battery terminal until the terminal will not turn. Do not overtighten the terminals or they will be very difficult to remove for future service.
7. Coat the terminals with spray-on battery terminal coating (available at most auto parts stores).
8. Put one of the black rubber boots over each of the terminals and connect the Battery Disconnect.

Specifications

Special tools

A hydrometer can be used to check the specific gravity of the battery electrolyte. A typical example is shown here.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌​⁠⁠​​​‌​‍‍​​‌‍⁠‌‌‍‍‌​⁠‍‌​‌‍⁠‌‍​⁠​‍‍

Wiring diagram tips

Wiring diagrams show how electrical components are connected together and to a large degree “how things work”. They do not show where things are located. Here are some tips when using these diagrams.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌‌​​​​​‌​‍‍​⁠‍⁠‍‌⁠⁠⁠​‍‍‌⁠​‍‌⁠‌​⁠⁠‌​​

Wiring diagrams may have multiple pages or sheets. The perimeter of each sheet defines a “grid” like a map; with A-G printed across the top and bottom margins of the sheet to define vertical columns and 1-5 printed on the right and left margins of the sheet to define rows. The sheet number and grid coordinates make up an “address” and are used for locating an area on the sheet where an item may be found. The address begins with the sheet number followed by the letter and number that define the coordinates on the sheet. In the example below, the address for the red circle is 2E3.

Every component has both an “ID” and a “name” on the sheet.

Typically relays (and contactors) are “split up” so that the relay winding is separated from the contacts. The “control” side of the relay is shown in one location and the “load” side of the relay is shown in another location. The two pieces may or may not be on the same page. The location of the contacts is described next to the winding and vice versa.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌‌​‌​​​‌​‍‍​⁠​​⁠⁠⁠‍‌‌​​‍‌‍‌‌​⁠‍‌‍​‌​

Sometimes a circuit line is interrupted and is continued on another sheet or another location on the same sheet. When this occurs you will need to match two termination points. At each termination point you will see a “continued” symbol. Near the symbol the circuit will be identified by a wire color, a description of the circuit or a unique letter. The circuit identification must be used to match the mating termination point. There is also an address of where to find the mating termination point. See examples below.

To find a connector that plugs into a component, see the Component Locations section to locate the component then follow the wire lead (if there is one) to the connector. If you need more detailed information about what a multi-pin connector looks like and where the wires are located in the connector, see the Connector Pin-Outs section.

Wiring diagram PN 56414095 REV C sheet 1 of 3

Components shown on sheet 1

Control board signal labels

Notes printed on the sheet

Corrected an obvious misprint: note 5 is printed “WIHTOUT” (now “without”) and note 4 prints “THE THE” (now “the”).‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌‌​‍​​​‌​‍‍​‍​‍‍‍‍​‍⁠‌​⁠‌‌‍⁠⁠⁠‌‌⁠⁠​‍

Wiring diagram PN 56414095 REV C sheet 2 of 3

Components shown on sheet 2

Wheel drive controller terminal labels

X7 wire labels

X8 programmer connector wire labels

The drawing prints BLU/GRN for X8 pin 1; the pin-out table on page 67 prints BLU/GRA 18-1.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌‌​⁠​​​‌​‍‍​‍‌⁠⁠​​‍​​​​⁠⁠‌⁠‍‍​​‌‌⁠‌​

Wiring diagram PN 56414095 REV C sheet 3 of 3

Components shown on sheet 3

Wiring harness diagram 56414096_REV_C

Components named on the harness diagram

Notes printed on the harness diagram

Options and accessories

Description	Illustration
Heavy duty front bumper
Tube Bumper Kit
Spray Wand

Recovery system

Functional description

Overview

The recovery system picks up the scrubbing solution from the squeegee tool and directs it to the Recovery Tank.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌‌‍‍​​​‌​‍‍​⁠⁠​‌​⁠‍​​‌​​‍‌‌‍‍⁠​‍​​​‍

Recovery tank

The Recovery Tank holds 70 gal (265 L) of wastewater and supports the Vacuum Motor, Recovery Tank Lid and Top Cover Assembly.

Vacuum motor

The Vacuum Motor draws air from the Recovery Tank to create a vacuum in the tank and at the Squeegee.

The Vacuum Motor switches on automatically when the scrub system is enabled and the machine moves forward. The Vacuum Motor will switch off after a predetermined time delay once machine motion stops.

The Vacuum Motor can also be switched on independent of the scrub system by pressing the vacuum/wand switch. This is used to pick up solution already on the floor, or when using a wand on the Squeegee Hose.

A current sensor monitors the Vacuum Motor current and will display a fault if the Vacuum Motor current draw is too high.

Squeegee and squeegee hose

The wastewater and air enter the vacuum system at the Squeegee tool through small openings (notches) located in the front Squeegee blade. The small openings are the entrance points for the water and air and help speed up the airflow, producing the suction to lift the wastewater off of the floor. The solution travels through the Squeegee Hose at high speed and into the Recovery Tank. The airflow continues through the Recovery Tank, vacuum fan inlet screen and Vacuum Motor, then is exhausted out of the Vacuum Hose. No wastewater ever actually moves through the Vacuum Motor, just the working air.

Float cage and ball

A shutoff Float Cage and Ball prevent the Recovery Tank from being overfilled and stops any water from being sucked into the Vacuum Motor. When the Float Ball rises (to full-tank level) it will seat itself inside the Cage assembly and block off the Vacuum Motor airflow. This causes a reduced Vacuum Motor current load which is sensed by the A2 control board which automatically shuts off the vacuum and scrub systems.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌‌‍⁠​​​‌​‍‍​⁠‌​‌‍‍⁠⁠​‌‌‍‌​‍‌‌‍‍‌⁠⁠‍‍

The LCD will then display the recovery tank full indicator icon to alert the operator that the recovery tank needs to be drained.

Recovery system wiring diagram

Circuit description

Vacuum Motors M5 and M6 get positive voltage from the Battery when the load sides of contactors K5 and K1 are closed. Contactors K5 and K1 close when the A2 Control Board Assembly connects the K5 and K1 contactor coils to battery ground. Vacuum Motors M5 and M6 are connected directly to battery ground.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌‌⁠​​​​‌​‍‍​​​‍​​‌‌‍⁠‌‍‍​​‌‍‌​​‌⁠⁠‍​

The A2 Control Board Assembly connects the K5 and K1 contactor coils to battery ground when:

• The A3 Switch/Display Panel Assembly sends the A2 Control Board Assembly a signal via the CAN BUS that the vacuum system has been switched on, or,
• The A1 Speed Controller sends the A2 Control Board Assembly a signal that the wheel drive is switched on, the scrub system is enabled and the vacuum system has not been switched off.

Note: The A2 Control Board Assembly monitors the voltage input from the Vacuum Motor Shunt wire connected to the ground side of Vacuum Motors M5 and M6. If the voltage is out of the acceptable range (.07 - .12 volts for a single vacuum motor or .15 - .24 volts for dual vacuum motors), the A2 Control Board Assembly will sense that the float ball is sealed against the float cage and that the recovery tank is full. The A2 Control Board Assembly will then shut down the vacuum and scrub systems and display a recovery tank full icon on the LCD.

Component locations

Vacuum motor and vacuum hose

The Vacuum Motor sits in a cavity in the Recovery Tank. To access the Vacuum Motor, remove the five Phillips screws and washers holding the top cover assembly on the recovery tank and remove the top cover assembly.

Note that there is room in the Recovery Tank for an optional second Vacuum Motor.

The Vacuum Hose is clamped to the outlet side of the Vacuum Motor and exhausts the airflow from the Vacuum Motor through to the underside of the machine.

Top cover assembly

The Top Cover Assembly is fastened to the top of the recovery tank and includes the Vacuum Filter Lid, Filter, Filter Screen and Recovery Tank Top. The Vacuum Cover Plate, Float Cage and contained Float Ball attach to the bottom of the Recovery Tank Top. The Vacuum Fan Top Gasket seals the Top Cover Assembly to the recovery tank.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌‌⁠‌​​​‌​‍‍​​​‌‌‍⁠‍⁠​‌​‌⁠​​‌​‌‍​⁠‍‌​

Float cage and ball

The Float Ball is retained inside the two-piece interlocking Float Cage. The assembled Float Cage and Float Ball attach to the bottom of the Recovery Tank Top.

Recovery tank lid

The Recovery Tank Lid is hinged and opens to allow access to the Recovery Tank.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌‌⁠‍​​​‌​‍‍​‌‌​‍​⁠​⁠‍‍‍‍‌⁠‍​‍⁠‌​‍⁠​‌

Squeegee and drain hoses

The Squeegee Hose and Drain Hoses are mounted on the rear of the Recovery Tank.

The Squeegee Hose connects the squeegee to the inlet port on the Recovery Tank.

The Drain Hose allows you to drain the Recovery Tank by removing the Drain Hose Cap.

Maintenance

To inspect and clean the vacuum filter and inlet screen

1. Open the tethered Vacuum Filter Lid.
2. Remove the Filter and Filter Screen by pulling them out of the recess in the Recovery Tank Top.
3. Clean the Filter and Filter Screen with vacuum or by washing them in warm water.
4. When the Filter and Filter Screen are clean and dry, reinstall them into the Recovery Tank Top.

Service Note: The Filter and Filter Screen must be completely dry before reinstalling.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌‌⁠⁠​​​‌​‍‍​‍‍​​​⁠⁠​⁠‌​‌​‌‍​‍‍​‍‍‌‍⁠

5. Replace the Vacuum Filter Lid.

To inspect and clean the vacuum motor float cage

1. Lift the Recovery Tank Lid to access the Float Cage and captive float ball. The Float Cage is attached to the underside of the Top Cover Assembly.
2. Carefully remove the Float Cage from the Top Cover Assembly. Note that the Float Cage is a two-piece design and can be snapped apart to separate for cleaning.
3. Clean any debris from the Float Cage slots with a rag, or by flushing the Float Cage with water. The Float Cage slots must be kept clean to prevent any airflow restriction.
4. Reassemble the Float Cage and captive float ball and reinstall into the Top Cover Assembly.
5. Inspect the Recovery Lid Gasket to make sure it is not damaged and is sealing correctly.

Troubleshooting

If water flows around the ends of the squeegee tool instead of being pulled into the tool, the vacuum system is not working correctly. This is usually due to either vacuum leaks, or restrictions in the squeegee tool, vacuum hoses or float cage.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌‍​​​​​‌​‍‍​‌‌‌‍⁠​‌‍‍‌‌​‌‍‌‍‌‍​⁠‌‌‍​

* A vacuum leak below the waterline will create turbulence in the recovery tank, causing water to enter the vacuum motor(s).

Insufficient water pick-up

Good water pick up performance depends on the proper amount of air flowing through the squeegee pickup tool. Air entering the vacuum system before the pickup tool will reduce its ability to pick up water. Anything that restricts the movement of air through the system will also reduce its ability to pick up water.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌‍​‌​​​‌​‍‍​⁠‌‍⁠‌⁠‌⁠​‍⁠‍‍‌‌‌‍​‍​‍‍‍​

Possible causes:

• Damaged squeegees
• Restricted air flow
  • Clogged or kinked squeegee vacuum hose
  • Clogged vacuum motor inlet or outlet port
• Air leaks
  • Recovery tank lid gasket is not sealing
  • Cracked squeegee vacuum hose
  • Cracked recovery tank
• Vacuum motor is weak

Troubleshooting steps

Begin with a good visual inspection of the system. Check the condition of the squeegees and the recovery hose. Take the recovery hose off and rinse it out. Check the recover tank cover gasket condition. Repair any problems found.

If no visual problems are found, test the system using a vacuum gauge PN 56205281 and open-hole adapter. (See the Special Tools Section below. The adapter can be made from a piece of PVC pipe.)

1. Remove the vacuum hose from the squeegee tool.
2. Hold the vacuum gauge against the end of the hose and turn on the vacuum motor. Note the reading on the gauge. If it is within 10% of specs, go to the next step. If it is too low, check for air leaks in the system.

3. Install a one inch open-hole adapter between the hose end and the vacuum gauge.
4. Turn the vacuum motor on and measure the vacuum. If it is within 10% of the specs, the vacuum system is working properly. If the reading is too low, check for a restriction in the system.

Removal and installation

Recovery tank

1. Drain the recovery tank.
2. Disconnect the squeegee hose from the squeegee tool, and from the top of the recovery tank (twist the hose to remove).

Note: Removing the squeegee tool at the mount will allow more room to maneuver when removing the recovery tank.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌‍​⁠​​​‌​‍‍​‌‍‍​⁠‌‍‍‌‍⁠‍⁠​‌​‍‌​⁠‌‍‌​

3. Disconnect the Vacuum Motor Wiring Connector located underneath the left rear bottom of the recovery tank.

4. Release the Tank Latch and tilt the tank toward the rear.

5. Disconnect the Tank Tether from the back of the operator seat.

6. Carefully lower the tank to the floor level.
7. Note that the tank is attached to the chassis by two pins. Lift up on the tank ends to separate and pull the tank free from the machine.

8. To reinstall the tank:
8. a. Align each side of the tank bracket with the chassis pins one at a time.
8. b. Grip the opening of the tank cover at the rear and quickly lift up to set (engage) the tank in its upright position.
8. c. Reconnect the Tank Tether to the back of the operator seat.
8. d. Swing the tank up to the vertical position to reengage the Tank Latch.
8. e. Reconnect the vacuum motor wiring connector and squeegee hose.

Vacuum motor

1. Drain the recovery tank.
2. Release the Tank Latch and tilt the tank to the rear.

3. Remove the five Screws from the Top Cover Assembly, then lift the Top Cover Assembly, straight up while guiding the float cage up through the opening in the recovery tank.

4. Disconnect the Vacuum (exhaust) Hose from the Vacuum Motor.
5. Disconnect the wiring harness connector from the Vacuum Motor and lift the Vacuum Motor out from its mounting cavity.
6. Inspect the following vacuum system gaskets and replace as necessary:
   • Vacuum Filter Lid Gasket
   • Vacuum Fan Top Gasket
   • RS Strip Gasket
   • Vacuum Fan Gaskets
7. Clean the vacuum motor Filter, Filter Screen and Vacuum (exhaust) Hose.
8. Inspect the carbon motor brushes. If the carbon brushes are less than 3/8 in (10 mm) in length, replace the brushes.
9. Reinstall the Vacuum Motor by following the above steps in reverse order.

Specifications

Shop measurements

Shop measurements are values that were measured on a real machine. While they are not “specifications”, they can help you recognize normal vs abnormal.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌‍‌‍​​​‌​‍‍​​⁠​​​​‌‍​‌‍⁠‍​‌‍‌⁠‌⁠⁠​‌‌

K1 vacuum contactor

Resistance at room temperature: 93 ohms

Vacuum motor

Current draw for one motor with open squeegee hose: 18.7 Amps

Special tools

Vacuum water lift gauge, Nilfisk-Advance part number 56205281

Scrub system, cylindrical

Functional description

Overview

The SC6500 cylindrical scrub deck models use two cylindrical brushes that counter-rotate to sweep up light debris into a removable hopper, and scrub at the same time. The two scrub brushes are powered on opposing ends by 1-1/2 HP permanent-magnet motors and drive belts.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌‍‌⁠​​​‌​‍‍​​‌⁠‍‌​‌⁠‍‍⁠‌‌‌‌‍‍⁠​‍‌‌‍‍

The scrub deck actuator raises and lowers the scrub deck, and automatically adjusts the deck height while scrubbing to maintain the desired scrub pressure.

Cylindrical scrub system wiring diagram

Circuit description

The coil sides of contactors K2 and K3 get positive voltage from the Battery when the load side of contactor K5 is closed. Contactor K5 closes when the A2 Control Board Assembly connects the K5 coil to battery ground. Contactors K2 and K3 are connected to battery ground through the A2 Control Board Assembly.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌‍‍​​​​‌​‍‍​‍‌⁠​‍​⁠‌⁠‍​‍​‌⁠‌‌⁠​‌‌‌​‍

The Right Brush Motor M9 and Left Brush Motor M10 get positive voltage from the Battery when the load sides of contactors K2 and K3 are closed respectively. Contactors K2 and K3 close when the A2 Control Board Assembly connects the K2 and K3 coils to battery ground. The Right Brush Motor M9 and Left Brush Motor M10 are connected directly to battery ground.

The Brush Actuator M2 gets voltage from the A2 Control Board Assembly which switches the polarity to move the scrub deck up or down. When the A2 Control Board Assembly receives a signal from the A3 Switch/Display Panel Assembly via the CAN BUS that the operator has pressed the scrub on switch, the A2 Control Board Assembly sends the appropriate voltage to the Brush Actuator M2 to lower the scrub deck to the operating position.

The Scrub Deck Sensing Resistor R2 senses the deck size so the operator does not need to program the deck size into the hidden menu.

As the brush motor current passes through the BRN current sense wire, which is in effect a low-value resistor, a small voltage drop is developed across it which is proportional to the motor current. This voltage change is inputted to pin J2-2 on the A2 Control Board Assembly. Any surrounding temperature change in the BRN current sense wire affects its resistance, so the temperature is sensed by a thermistor built into the A2 Control Board Assembly. This allows error correction for the temperature resistance changes in the BRN current sense wire. When A2 Control Board Assembly senses a current draw out of the desired range it automatically turns on the M2 actuator motor to raise or lower the scrub deck. This process is ongoing in maintaining the operator’s selected scrub motor current load setting to sustain the desired brush working pressure.

Component locations

The 1-1/2 HP permanent-magnet Scrub Motors drive Poly V Sheaves and Drive Belts that drive the broom drive lug assemblies coupled to the brushes.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌‍‍‌​​​‌​‍‍​‌​​‍‌⁠‌‍⁠‌⁠‍⁠‍‍‌⁠⁠‌⁠⁠‌​⁠

The Scrub Deck Actuator Assembly raises and lowers the scrub deck and automatically adjusts the deck height during scrubbing to maintain the correct scrub pressure.

The Hopper Assembly holds the dust and debris swept up by the scrub brushes, and can be removed for dumping and cleaning.

The Side Skirts direct the waste water to the squeegee and help keep the water confined within the cleaning path. The Side Skirt height is adjustable, and the Side Skirts can be removed for cleaning or replacement.

Maintenance and adjustments

General scrub system maintenance

The scrubbing system must be serviced at regular intervals to maintain good scrubbing performance. Follow the maintenance steps listed below.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌‍‍‍​​​‌​‍‍​‍​⁠‌‍⁠‍​‌​​​​‍⁠‌‍​‍‌​‍⁠​

Daily maintenance

• Dump the sweeping debris from the hopper.
• Rinse and clean any built-up debris from the hopper drain holes.

Weekly maintenance

• Clean the drain holes in the solution delivery trough on top of the scrub deck.
• Clean any built-up dirt from the inside of the scrub brush housing.
• Remove any string wrapped around the scrub brushes, drive hubs and idler hubs.
• Remove both the scrub brushes and rotate end-for-end. Refer to the Removal and Installation/Scrub Brushes section.

Monthly maintenance

• Inspect the scrub brush bristles for wear, the brushes should be replaced when the bristle length is 1 in (26 mm) or less.

Scrub brush belt replacement

The drive belt is a “stretch” belt. There is no tension adjustment. The belt is rolled on and off the pulleys.

1. Remove the Side Skirt Assembly on the side needing belt replacement.
2. Remove the two hex nuts (10 mm socket) and Phillips screw holding the Belt Guard, then remove the Belt Guard.

3. Use a 1/2 in drive extension and ratchet in the large pulley slot, to rotate the pulley while pulling outward on the belt to roll the belt off of the pulleys.

4. Place the new belt on the large pulley and then use a plastic wire tie to hold the belt on the pulley.

5. Loop the belt over the small pulley and hold it on.
6. Use a 1/2 in drive extension and ratchet in the large pulley slot, to rotate the pulley to roll the belt onto the pulley.

7. If the belt is not seated properly in the pulley grooves, gently push or pull in the direction that the belt must move while rotating the belt.
8. Reinstall the Belt Guard and Side Skirt Assembly, then test the scrub system for correct operation.

Lift actuator adjustment

The lift actuator adjustment makes sure that the deck can be properly positioned when extended for scrubbing operations and when retracted for machine transport. The adjustment sets the position of the drive nut on the actuator lead screw when either of the internal travel limit switches open in order to stop the motor rotation. The retracted position is set by running the motor in the retracted position until the motor stops and then screwing the drive nut onto the lead screw until it is in the correct location. Once the retracted position is established, the extended position is set by adjusting an internal cam under the rubber cover of the actuator motor.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌‍⁠​​​​‌​‍‍​⁠​⁠‌‍‍⁠‍⁠⁠​‌⁠‍​​⁠‍‌‌‍‌​​

Using the actuator power cord adapter

The adjacent drawing shows the special actuator power cord adapter (p/n 56407502) that is needed to connect the machine’s battery pack and actuator motor for setting the actuator drive nut limit settings. To connect the actuator power cord adapter:

1. Open the machine battery compartment and disconnect the battery connector. The battery pack is needed to power the scrub deck actuator motor to correctly set the IN and OUT limit switches.
2. Connect the actuator motor to be tested to the power cord adapter end.
3. Connect the alligator clips from the cord adapter (red clip to the positive and black to negative) to battery connector or battery posts. Use the rocker switch on the actuator power cord adapter to change the motor rotation when setting the correct actuator drive nut dimensions.

Service Note: You can also use the above actuator power cord adapter to help position the drive nut/spring housing assembly (in or out) for ease in actuator motor installations.

Lift actuator drive nut adjustment

This procedure sets the relative position between the drive nut on the actuator lead screw and the base of the actuator motor assembly.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌‍⁠‌​​​‌​‍‍​⁠‍​‍‌⁠⁠⁠‌​​‍⁠​‍‌‌⁠​​‌⁠‍‍

1. Make a note of how the actuator housing assembly should be mounted on the machine.

Left drawing: actuator orientation for 40 in disk and cylindrical decks. Right drawing: actuator orientation for 45 in and 48 in disk and cylindrical decks.

2. Familiarize yourself with the actuator assembly pieces and the assembly order of the springs, drive nut and spring housing. Refer to the photo below. If the housing and springs are already assembled, disassemble them.

3. Lubricate the lead screw threads using bearing grease.
4. Install the spring cap into the upper spring. (The upper spring is shorter and lighter than the lower spring). Then install the upper spring and cap onto the lead screw with the cap toward the motor housing.
5. Rotate the drive nut onto the lead screw threads a few turns with the pin hole away from the motor housing as shown in the above photo.

6. Hold the drive nut to prevent it from rotating, then using the actuator power cord adapter (p/n 56407502), run the motor toward the retracted position until the motor stops. This establishes the location where the retracted travel limit switch opens. Now, rotate the nut on the lead screw until the distance between the nut and the motor housing is 1 3/4 in (4.5 cm).

7. Hold the drive nut to prevent it from rotating, then using the actuator power cord adapter (p/n 56407502), run the motor toward the extended position until the motor stops. This establishes the location where the extended travel limit switch opens.
7. a. Measure the distance between the nut on the lead screw and the motor housing. It should be 5 1/2 in (14 cm).

7. b. If the distance is not correct, remove the rubber cam adjuster cover with a screwdriver in the motor housing to gain access to the cam adjustment.

7. c. Rotate the cam using a 1/2 in or 13 mm socket (Not a screw driver!). Each click of the cam position will change the drive nut distance by about 1/16 in (1.6 mm). Rotate the cam clockwise to increase the distance and counterclockwise to decrease the distance.

8. Recheck the retracted and extended position adjustments by holding on to the drive nut to prevent it from rotating and driving the motor to each limit position using the actuator power cord adapter. Repeat adjustments until correct.
9. Once the drive nut adjustment is complete, finish assembling the spring housing being careful not to turn the drive nut.
   • a. Install the lower spring onto the lead screw.
   • b. Install the housing over the lead screw, springs and drive nut. Align the slotted holes in the housing with the pin holes in the drive nut.

• c. Install the two nut retainers; inserting their pins into the drive nut pin holes. Secure the two nut retainers together using two screws.

• d. Slightly compress the upper spring and install the 4 spring housing retaining screws. You can compress the spring by holding the assembly on a stable surface and pushing down on the housing or by using a small “pry bar” through the retaining screw holes. Be careful that the screws go above the spring cap and do not damage it!

10. Reinstall the Cam Adjuster Cover.
11. After adjusting the actuator Spring Housing Assembly dimensions, refer to the Removal and Installation/Scrub Deck Lift Actuator section to reassemble it in the machine. Refer to the adjacent drawing to correctly mount the top of actuator motor to the chassis by model size.

• Actuator orientation for 40 in disc and cylindrical decks (left drawing)
• Actuator orientation for 45 in and 48 in disc and cylindrical decks (right drawing)

Service Note: Note the correct orientation of the Spring Housing Assembly when installing the complete motor assembly and also run the Spring Housing Assembly to the Retracted (in) position before you install it in the machine.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌⁠​​​​​‌​‍‍​​⁠⁠‍⁠‌‍‌​‌‍​⁠‍‌‍‌​‍⁠​​‌⁠

Side skirt replacement and adjustment

During normal use the side skirt blades will wear in time. The operator will notice a small amount of water leaking out underneath the side skirts. You can easily adjust the side skirt height to lower the blades to allow the squeegee to pick up the water more effectively.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌⁠​‌​​​‌​‍‍​​​​‌​⁠‌‍‌⁠‍⁠‍‌⁠⁠‍‍‌‌‍⁠‍‌

To reverse or replace the scrub system side skirt blade(s):

1. Loosen the two side skirt Retainer Knobs (two per side) and remove the Side Skirt Assemblies from the scrub deck. Remove the Side Skirt Assemblies by first sliding them forward, then pulling them off.
2. Remove all the hardware that holds the Skirt Blades to the Bracket Weldments. Note that the Skirt Blade is held on with tool-less retainers. Simply loosen the large Thumb Nuts, then turn the Knobs on the outside of the Skirt Strap until they are horizontal, then push them through the slots.
3. The main Skirt Blade has four working edges as shown. Turn the Skirt Blade so a clean, undamaged edge faces toward the center of the machine. Replace the Skirt Blades as a set if all four edges are nicked, torn or worn beyond their ability to be adjusted.
4. Reinstall the Side Skirt Assemblies onto the machine and check the height of the Skirt Blades for correct contact on the floor when the brush deck is lowered to the scrub position. The Skirt Blades should fold over just enough when scrubbing that all the waste water is contained inside the skirting. If necessary, adjust the height of the Side Skirt Assemblies as follows:
   • a. Loosen the Retainer Knobs.
   • b. Rotate the Height Adjusting Knobs to raise or lower the Side Skirt Assembly as necessary.
   • c. When the Skirt Blade contact is correct, tighten the Retainer Knobs.

Note: Make small adjustments to obtain good blade wiping. Do not lower the blades too much to where they fold over excessively as this can cause excessive blade wear.

Troubleshooting

Removal and installation

Scrub brushes

1. Make sure the scrub deck is in the raised position and the key switch is off.
2. Loosen the Retainer Knobs, then slide the Side Skirt Assembly forward slightly, then off of the scrub deck.
3. Loosen the Thumb Nut on top of the Broom Idler Assembly until the Broom Idler Assembly drops down far enough to disengage it from the Notches, then remove the Broom Idler Assembly.
4. Remove the Brush from the housing.
5. To reinstall a Brush, slide it into the housing, lift it slightly, then push and turn the Brush until it seats.
6. Reinstall the Broom Idler Assembly and Side Skirt Assembly.

Scrub brush deck

1. Loosen the four side skirt Retainer Knobs (two per side) and remove the Side Skirt Assemblies from the deck.
2. Slide out the Hopper.
3. With the scrub brushes installed in the deck, press the Scrub On button to lower the deck to the floor.

Service Note: Once the brush deck is in the lowered position, don’t turn the key switch off until you disconnect the battery pack (push in the Emergency Disconnect). This will prevent the scrub deck from automatically rising when the key is turned off.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌⁠‌‌​​​‌​‍‍​​‍​⁠‌⁠‌​‌‌‍‌‍⁠​‌​​​‌‍⁠‍​

4. Turn the key switch off.
5. Remove the Solution Feed Hose at the solution solenoid valve located underneath the left side of the machine ahead of the rear wheel.
6. Remove bottom lift actuator Cotter Hair Pin, then push the Retainer Pin from its housing and mount bracket holes.
7. Disconnect the actuator wire harness connector. Note that this will prevent the actuator from being switched on and rising when it is disconnected from its deck mount.

Service Note: Connect the Advance power cord adapter (p/n 56407502) to the lift motor harness, then position (relieve the pressure on) the Retainer Pin for ease of removal.

8. Note the correct brush motor wire connections at each individual motor, then remove all the wiring from the motor terminals.
9. Locate the ID (identification) Resistor Plug on the scrub brush deck and separate its connector.
10. Remove the four Hex Nuts, hex screws and bushings from the left and right front deck supports, then swing the Pivot Support Arms away from their mounting holes.

Service Note: Removing both the left and right side brooms and both front chassis corner rollers will allow easier access to the mounting hardware on the four front scrub deck support arms.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌⁠‌‍​​​‌​‍‍​⁠⁠⁠‌​‌‍​⁠​​⁠⁠⁠​⁠‍⁠‍‍⁠⁠‌⁠

11. Run the Scrub Deck Actuator to its retracted (up) position to get the clearance needed to pull the scrub deck assembly out from underneath the machine.

Service Note: Connect the power cord adapter (p/n 56407502) to the actuator motor and use the adapter to shorten the Scrub Deck Actuator length. Hold the Spring Housing Assembly when you run the Scrub Deck Actuator motor to maintain the correct retracted and extended position settings. See the Lift Actuator Adjustment section in this manual for additional details.

An alternate method to get the needed actuator clearance to slide the deck out from under the machine would be to safely jack up the front of the machine.

12. Carefully slide the complete deck assembly out from underneath the machine from either side.

Note: Observe the position of the disconnected lift actuator housing and swing it to the rear to clear its mount bracket pocket.

Scrub deck lift actuator

Note: All new replacement actuator motors are not shipped with the lift nut pre-adjusted for any specific machine model application.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌⁠‌⁠​​​‌​‍‍​‌‌‍⁠‌‍⁠​‌‍​⁠‌‌⁠​⁠‍‍‍‍​​‍

Note: The scrub deck must be removed to access the top mount bracket on the scrub deck lift motor.

1. Remove the scrub deck by following the steps in the Scrub Brush Deck section.
2. Locate and remove the upper Cotter Hair Pin from underneath the middle of the machine.
3. Slide the actuator Mount Pin from the housing and frame mounting bracket holes allowing the motor to drop down completing its removal.
4. Refer to the Drive Nut Adjustment section for instructions on how to install a new drive nut and set the extended and retracted positions.
5. Install the scrub deck actuator by following the above steps in reverse order.

• Actuator orientation for 40 in disc and cylindrical decks (left drawing)
• Actuator orientation for 45 in and 48 in disc and cylindrical decks (right drawing)

Service Note: You can use the actuator power cord adapter (p/n 56407502) to help position (extend or retract) the lift actuator housing for ease in installing the bottom Mount (clevis) Pin.

Scrub brush motor

Note: It is not necessary to remove the complete scrub deck assembly from the machine to service an individual scrub brush motor.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌⁠‍​​​​‌​‍‍​​​‌​‌‌‍⁠‌​⁠⁠‍⁠⁠‌‍​⁠​⁠‍‍⁠

1. Remove the Side Skirt Assembly on the side of the deck that needs the scrub motor replaced.
2. Slide out the Hopper.
3. With the scrub brushes installed in the deck, press the Scrub On button to lower the deck to the floor.

Service Note: Once the brush deck is in the lowered position, don’t turn the key switch off until you disconnect the battery pack (push in the Emergency Disconnect). This will prevent the scrub deck from automatically rising when the key is turned off.

4. Turn the key switch off.
5. Remove the two hex nuts (0.39 in socket, 10 mm) and Phillips screw holding the Belt Guard and remove the Belt Guard.
6. Remove the four motor mount Screws holding the Scrub Motor to its deck mount. Also note that the Scrub Motor may stick to the motor mount, so be careful and watch your fingers as the motor will drop.
7. Turn the Scrub Motor clockwise to access the motor terminal studs. Note the wire connections for correct reassembly, then remove both motor wires.
8. Lower the deck assembly to the deck actuator’s maximum down position (travel) to get the clearance needed to remove the motor from the machine. You can do this either of two ways:
   • Reconnect the battery, then lower the scrub deck in the service test mode. (Refer to the Control System/Service Test Mode section.)
   • Connect the actuator power cord adapter to the deck actuator motor and run (lower) the deck housing. (Refer to the Drive Nut Adjustment section for details.)
9. Pull and push the Scrub Motor back toward the rear of the machine to clear the chassis supports and remove it at the Hopper.
10. To install a Scrub Brush Motor:
    • a. Follow the above steps in reverse order with the exception that the drive belt tension must be reduced to allow the installation of the four motor mount Screws.
    • b. Refer to the Scrub Brush Belt Replacement section and follow the instructions on how to replace or tension the belt.

Specifications

Shop measurements

Shop measurements are values that were measured on a real machine. While they are not “specifications”, they can help you recognize normal vs abnormal.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌⁠‍‌​​​‌​‍‍​‌‌⁠‌​‌‌‌‌⁠‌‌​‍⁠⁠‍‍‌⁠⁠‍⁠‍

Brush contactor (K2, K3 or K4)

Resistance at room temperature: 93 ohms

Scrub brush motor

• 40C and 1100C deck with no load (brushes out): Not measured
• 45C deck with no load (brushes out): 6.1-6 Amps
• 45C deck working on dry epoxy floor: 25-45 Amps
• 48C 1300C deck not measured

Brush actuator motor

• 45 inch cylindrical deck
  • Current draw going up: 3.5-4.0 Amps
  • Current draw going down: 1.2-2.2 Amps

Special tools

Actuator Power Cord Adapter, p/n 56407502‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌⁠‍‍​​​‌​‍‍​​‌⁠‍‌​​​‌⁠‌⁠​⁠⁠⁠⁠‌​‍​⁠‌‍

Scrub system, disc

Functional description

Overview

The SC6500 disc models use rotary brushes powered by permanent-magnet motors and gearbox assemblies. The 40” decks have two scrub brushes that are both powered by one 3 HP motor/gearbox assembly. The 45” and 48” decks have three brushes, each powered by a separate 1-1/2 HP motor/gearbox assembly.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌⁠‍⁠​​​‌​‍‍​​‍⁠‌⁠‍⁠‍⁠⁠⁠‍‍​‍​​⁠‌‍⁠​‌‌

The scrub deck lift actuator raises and lowers the scrub deck, and automatically adjusts the deck height while scrubbing to maintain the desired scrub pressure.

Disc scrub system wiring diagram

Circuit description

The coil sides of contactors K2, K3 and K4 get positive voltage from the Battery when the load side of contactor K5 is closed. Contactor K5 closes when the A2 Control Board Assembly connects the K5 coil to battery ground. Contactors K2, K3 and K4 are connected to battery ground through the A2 Control Board Assembly.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌⁠⁠​​​​‌​‍‍​​‌‌⁠‌​⁠‌​‌​‍‍​‌‌⁠​‍​‍‍‌‌

The Right Brush Motor M9, Center Brush Motor M10 and Left Brush Motor M11 get positive voltage from the Battery when the load sides of contactors K2, K3 and K4 are closed respectively. Contactors K2, K3 and K4 close when the A2 Control Board Assembly connects the K2, K3 and K4 coils to battery ground. The Right Brush Motor M9, Center Brush Motor M10 and Left Brush Motor M11 are connected directly to battery ground.

The Brush Actuator M2 gets voltage from the A2 Control Board Assembly which switches the polarity to move the scrub deck up or down. When the A2 Control Board Assembly receives a signal from the A3 Switch/Display Panel Assembly via the CAN BUS that the operator has pressed the scrub on switch, the A2 Control Board Assembly sends the appropriate voltage to the Brush Actuator M2 to lower the scrub deck to the operating position.

The Scrub Deck Sensing Resistor R2 senses the deck size so the operator does not need to program the deck size into the hidden menu.

As the brush motor current passes through the BRN current sense wire, which is in effect a low-value resistor, a small voltage drop is developed across it which is proportional to the motor current. This voltage change is inputted to pin J2-2 on the A2 Control Board Assembly. Any surrounding temperature change in the BRN current sense wire affects its resistance, so the temperature is sensed by a thermistor built into the A2 Control Board Assembly. This allows error correction for the temperature resistance changes in the BRN current sense wire. When A2 Control Board Assembly senses a current draw out of the desired range it automatically turns on the M2 actuator motor to raise or lower the scrub deck. This process is ongoing in maintaining the operator’s selected scrub motor current load setting to sustain the desired brush working pressure.

Component locations

On the 45” and 48” decks, three 1-1/2 HP Gearmotors drive the scrub brushes directly. The 40” decks have a single 3 HP Gearmotor with two gearboxes (one on either end) that power the two scrub brushes.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌⁠⁠‌​​​‌​‍‍​‌‍‌⁠‌​​⁠​​‍‍‌​‍​‍⁠‌​‌​‌‌

The Scrub Deck Actuator Assembly raises and lowers the scrub deck, and automatically adjusts the deck height during scrubbing to maintain the correct scrub pressure.

The Side Skirts direct the waste water to the squeegee and help keep the water confined within the cleaning path. The Side Skirt height is adjustable and the Side Skirts can be removed for cleaning or replacement.

Maintenance and adjustments

Lift actuator adjustment

The lift actuator adjustment makes sure that the deck can be properly positioned when extended for scrubbing operations and when retracted for machine transport. The adjustment sets the position of the drive nut on the actuator lead screw when either of the internal travel limit switches open in order to stop the motor rotation. The retracted position is set by running the motor in the retracted position until the motor stops and then screwing the drive nut onto the lead screw until it is in the correct location. Once the retracted position is established, the extended position is set by adjusting an internal cam under the rubber cover of the actuator motor.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌⁠⁠‍​​​‌​‍‍​⁠​​‍‍‌⁠​​‍‍​‌​​‍‍​‍​⁠‌‍‍

Using the actuator power cord adapter

The adjacent drawing shows the special actuator power cord adapter (p/n 56407502) that is needed to connect the machine’s battery pack and actuator motor for setting the actuator drive nut limit settings. To connect the actuator power cord adapter:

1. Open the machine battery compartment and disconnect the battery connector. The battery pack is needed to power the scrub deck actuator motor to correctly set the IN and OUT limit switches.
2. Connect the actuator motor to be tested to the power cord adapter end.
3. Connect the alligator clips from the cord adapter (red clip to the positive and black to negative) to battery connector or battery posts. Use the rocker switch on the actuator power cord adapter to change the motor rotation when setting the correct actuator drive nut dimensions.

Service Note: You can also use the above actuator power cord adapter to help position the drive nut/spring housing assembly (in or out) for ease in actuator motor installations.

Lift actuator drive nut adjustment

This procedure sets the relative position between the drive nut on the actuator lead screw and the base of the actuator motor assembly.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‌⁠⁠⁠​​​‌​‍‍​‍‌‌‍‌⁠‌​⁠‍​‍​⁠‍⁠‌⁠‍​⁠‌​‌

1. Make a note of how the actuator housing assembly should be mounted on the machine.

• Actuator orientation for 40 in disc and cylindrical decks (left drawing)
• Actuator orientation for 45 in and 48 in disc and cylindrical decks (right drawing)

2. Familiarize yourself with the actuator assembly pieces an the assembly order of the springs, drive nut and spring housing. Refer to the photo below. If the housing and springs are already assembled, disassemble them.

3. Lubricate the lead screw threads using bearing grease.
4. Install the spring cap into the upper spring. (The upper spring is shorter and lighter than the lower spring). Then install the upper spring and cap onto the lead screw with the cap toward the motor housing.
5. Rotate the drive nut onto the lead screw threads a few turns with the pin hole away from the motor housing as shown in the above photo.

6. Hold the drive nut to prevent it from rotating, then using the actuator power cord adapter (p/n 56407502), run the motor toward the retracted position until the motor stops. This establishes the location where the retracted travel limit switch opens. Now, rotate the nut on the lead screw until the distance between the nut and the motor housing is 1 3/4” (4.5 cm).

7. Hold the drive nut to prevent it from rotating, then using the actuator power cord adapter (p/n 56407502), run the motor toward the extended position until the motor stops. This establishes the location where the extended travel limit switch opens.
   • a. Measure the distance between the nut on the lead screw and the motor housing. It should be 5 1/2 inches (14 cm).

• b. If the distance is not correct, remove the rubber cam adjuster cover with a screwdriver in the motor housing to gain access to the cam adjustment.

• c. Rotate the cam using a 1/2 in (13 mm) socket (Not a screw driver!). Each click of the cam position will change the drive nut distance by about 1/16” (1.6mm). Rotate the cam clockwise to increase the distance and counterclockwise to decrease the distance.

8. Recheck the retracted and extended position adjustments by holding on to the drive nut to prevent it from rotating and driving the motor to each limit position using the actuator power cord adapter. Repeat adjustments until correct.
9. Once the drive nut adjustment is complete, finish assembling the spring housing being careful not to turn the drive nut.
   • a. Install the lower spring onto the lead screw.
   • b. Install the housing over the lead screw, springs and drive nut. Align the slotted holes in the housing with the pin holes in the drive nut.

• c. Install the two nut retainers; inserting their pins into the drive nut pin holes. Secure the two nut retainers together using two screws.

• d. Slightly compress the upper spring and install the 4 spring housing retaining screws. You can compress the spring by holding the assembly on a stable surface and pushing down on the housing or by using a small “pry bar” through the retaining screw holes. Be careful that the screws go above the spring cap and do not damage it!

10. After each adjustment, hold the Spring Housing Assembly, run the actuator in and out and check both dimensions.
11. Reinstall the Cam Adjuster Cover.
12. After adjusting the actuator Spring Housing Assembly dimensions, refer to the Removal and Installation/Scrub Deck Lift Actuator section to reassemble it in the machine. Refer to the adjacent drawing to correctly mount the top of actuator motor to the chassis by model size.

• Actuator orientation for 40 in disc and cylindrical decks (left drawing)
• Actuator orientation for 45 in and 48 in disc and cylindrical decks (right drawing)

Service Note: Note the correct orientation of the Spring Housing Assembly when installing the complete motor assembly and also run the Spring Housing Assembly to the Retracted (in) position before you install it in the machine.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‍​​‍​​​‌​‍‍​⁠‍​⁠​‌​​​‍‌‌‌​⁠‍‌‍⁠​​‌​⁠

Side skirt replacement and adjustment

During normal use the side skirt blades will wear in time. The operator will notice a small amount of water leaking out underneath the side skirts. You can easily adjust the side skirt height to lower the blades to allow the squeegee to pick up the water more effectively.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‍​​⁠​​​‌​‍‍​​​​⁠‍‌⁠‌⁠‍‌‍​⁠​​‌​​​‌⁠‍⁠

To reverse or replace the scrub system side skirt blade(s):

1. Loosen the two side skirt Retainer Knobs (two per side) and remove the Side Skirt Assemblies from the scrub deck. Remove the Side Skirt Assemblies by first sliding them forward, then pulling them off.
2. Remove all the hardware that holds the Skirt Blades to the Skirt Weldments. Note that the Skirt Blade is held on with tool-less retainers. Simply loosen the large Thumb Nuts, then turn the Knobs on the outside of the Skirt Strap until they are horizontal, then push them through the slots. The small Inside Blade is held on by two screws and nuts and has two working edges.
3. The main Skirt Blade has four working edges as shown. Turn the Skirt Blade so a clean, undamaged edge faces toward the center of the machine. Replace the Skirt Blades as a set if all four edges are nicked, torn or worn beyond their ability to be adjusted.
4. Reinstall the Side Skirt Assemblies onto the machine and check the height of the Skirt Blades for correct contact on the floor when the brush deck is lowered to the scrub position. The Skirt Blades should fold over just enough when scrubbing that all the waste water is contained inside the skirting. If necessary, adjust the height of the Side Skirt Assemblies as follows:
   • a. Loosen the Retainer Knobs.
   • b. Rotate the Height Adjusting Knobs to raise or lower the Side Skirt Assembly as necessary.
   • c. When the Skirt Blade contact is correct, tighten the Retainer Knobs.

Note: Make small adjustments to obtain good blade wiping. Do not lower the blades too much to where they fold over excessively as this can cause excessive blade wear.

Troubleshooting

Troubleshooting (continued)

Troubleshooting (continued)

Removal and installation

Scrub brush deck

1. Loosen the four side skirt Retainer Knobs (two per side) and remove the Side Skirt Assemblies from the deck.
2. Remove the scrub brushes from the brush holders.
3. Place wood blocking (2x4) under both outside brush drive discs (brush holders) and lower the deck to the floor by pressing the Scrub On button.

Service Note: Once the brush deck is in the lowered position, don’t turn the key switch off until you disconnect the battery pack (push in the Emergency Disconnect). This will prevent the scrub deck from automatically rising when the key is turned off.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‍​‌⁠​​​‌​‍‍​​‍‌‍⁠‌​​‌​‌‍​‍​‍⁠​‍‍‍⁠⁠⁠

4. Turn the key switch off.
5. Remove the Solution Feed Hose at solution distribution bladder located on the scrub deck.
6. Remove bottom Scrub Deck Actuator Cotter Hair Pin, then push the Retainer Pin from its housing and mount bracket holes.
7. Disconnect the Scrub Deck Actuator wire harness connector. Note that this will prevent the Scrub Deck Actuator from being switched on and rising when it is disconnected from its deck mount.
8. Note the correct brush motor wire connections at each individual motor, then remove all the wiring from the motor terminals.
9. Locate the ID (identification) Resistor Plug on the scrub brush deck and separate its connector.
10. Remove the four Hex Nuts, hex screws and bushings from the left and right front deck supports, then swing the Pivot Support Arms away from their mounting holes.
11. Remove the previously-installed wood blocking from underneath the drive discs. Note that this must be done to get the needed clearance to remove the scrub deck.
12. Carefully slide the complete deck assembly out from underneath the machine from its left side.

Note: Observe the position of the disconnected lift actuator housing and swing it to the rear to clear its mount bracket pocket.

Scrub deck lift actuator

Note: All new replacement actuator motors are not shipped with the lift nut pre-adjusted for any specific machine model application.

Note: The scrub deck must be removed to access the top mount bracket on the scrub deck lift motor.

1. Remove the scrub deck by following the steps in the Scrub Brush Deck section.
2. Locate and remove the upper Cotter Hair Pin from underneath the middle of the machine.
3. Slide the actuator Mount Pin from the housing and frame mounting bracket holes allowing the motor to drop down completing its removal.
4. Refer to the Drive Nut Adjustment section for instructions on how to install a new drive nut and set the extended and retracted positions.
5. Follow the above steps in reverse order to install the scrub deck actuator.

Scrub brush motor and gearbox

To remove and install a gearbox assembly

1. Remove the scrub brushes from the Brush Holder(s).
2. Use a 0.51 in (13 mm) socket wrench to remove the three Screws from each Thermoid Disk (flexible coupler), then remove the Brush Holder(s) from the Drive Hub(s).
3. Remove the hex screw and hardened washer holding the Drive Hub onto the Gearbox Assembly, then pull the Drive Hub off of the Gearbox Output Shaft. Make sure you save the key stock.
4. Remove the three Hex Screws that secure each Gearbox Assembly to the deck mounting plate.
5. Separate the Gearbox Assembly from the Deck Weldment by pulling it straight up.
6. Reassemble the Gearbox Assembly to the Deck Weldment by following the above steps in reverse order. Make sure to reinstall the key stock.

To disassemble and reassemble a gearbox assembly

1. Remove the three socket head cap screws securing the Gearbox to the Brush Motor, then separate the Gearbox from the Brush Motor. Make sure to save the internal Gearbox key stock for reassembly.
2. Reassemble the Gearbox and Brush Motor by following the above steps in reverse order.

Service Note: Apply a small amount of grease or Never-Seez® anti-seize compound to the Gearbox input and output shafts when you reassemble or install a Gearbox Assembly. This will aid future disassembly and Drive Hub removal.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‍​‍​​​​‌​‍‍​​‌⁠‍‍​⁠​⁠​​‍⁠​​‌‍​​⁠​⁠​​

Specifications

Shop measurements

Brush Contactor (K2, K3 or K4) resistance at room temperature: 93 ohms‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‍​‍‌​​​‌​‍‍​‍‌⁠‍‌‍‌​⁠‌‌​‍‍⁠‌​‍‍‌​​⁠‌

Scrub brush motor

• 40D and 1100D deck with no load (brushes out): 11.7-12.2 Amps
• 45D and 1300D deck with no load (brushes out): Not measured

Special tools

Actuator Power Cord Adapter, p/n 56407502

Solution system

Functional description

Overview

The solution system provides the Water and detergent mixture to the scrub brushes. Water and detergent are added to the solution tank for Standard (non-EcoFlex) SC6500 models. EcoFlex models have a separate detergent tank. On both standard and EcoFlex models the Drain Hose allows you to drain the Solution Tank by removing the Drain Plug.‌‌​⁠​⁠‍⁠⁠⁠‍​⁠‍‍‌⁠‍⁠⁠​​​​‍​‍⁠​​​‌​‍‍​​‍​​​​⁠‌​‍​​​​‍​‍​‌⁠‍​⁠⁠

On standard (non-EcoFlex) models, the solution is gravity fed through the plumbing to the scrub deck. The solution solenoid is spring loaded closed to block the fluid. The A2 Control Board provides pulsed-width-modulated (PWM) voltage to the Solution Solenoid to regulate the solution flow rate.

On EcoFlex models, a solution pump is used to move fluid from the solution tank to the scrub deck. The A2 Control Board provides pulsed-width-modulated (PWM) voltage to the Solution Control Pump to regulate the solution flow rate. Note that the Solution Solenoid Valve is full-open whenever the solution system is switched on.

On EcoFlex models, when the detergent system is switched on, the solenoid style Detergent Pumps inject detergent into the solution sytem plumbing. The A2 Control Board provides PWM voltage to the Detergent Pumps to regulate the detergent flow.